Download - Kohler Engines

Technicians
Certification Test
Study Guide
TP-2500 REV. 11/2010
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Contents
Section 1. Safety and General Information ............................................................................
Section 2. Tools & Aids ..........................................................................................................
Section 3. Troubleshooting .....................................................................................................
Section 4. Air Cleaner and Air Intake System ........................................................................
Section 5. Fuel System and Governor ....................................................................................
Section 5A. LPG Fuel Systems ...............................................................................................
Section 5B. Electronic Fuel Injection (EFI) Fuel System ......................................................
Section 6. Lubrication System ................................................................................................
Section 7. Retractable Starter .................................................................................................
Section 8. Electrical System and Components .....................................................................
Section 9. Disassembly ...........................................................................................................
Section 10. Inspection and Reconditioning ...........................................................................
Section 11. Reassembly ...........................................................................................................
Section 12. Clutch ....................................................................................................................
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ȱ ȱ Ž ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖřŖȦŖǯŖśśȱ––ȱǻŖǯŖŖŗŘȦŖǯŖŖŘŘȱ’—ǯǼ
ȱ ȱ Š¡ǯȱŽŠ›ȱ’–’ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŝŖȱ––ȱǻŖǯŖŖŘŞȱ’—ǯǼ
˜——ŽŒ’—ȱ˜Ȭ˜Ȭ›Š—”™’—ȱ’Žȱ•ŽŠ›Š—ŒŽȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŘŜȦŖǯŜřȱ––ȱǻŖǯŖŗŖŘȦŖǯŖŘŚŞȱ’—ǯǼ
˜——ŽŒ’—ȱ˜Ȭ˜Ȭ’œ˜—ȱ’—ȱž——’—ȱ•ŽŠ›Š—ŒŽȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŗśȦŖǯŖŘŞȱ––ȱǻŖǯŖŖŖŜȦŖǯŖŖŗŗȱ’—ǯǼ
’œ˜—ȱ’—ȱ—ȱǯǯ
ȱ ȱ Ž ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŗŝǯŖŗśȦŗŝǯŖŘřȱ––ȱǻŖǯŜŜşşȦŖǯŜŝŖŘȱ’—ǯǼ
ȱ ȱ Š¡ǯȱŽŠ›ȱ’–’ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŗŝǯŖřŜȱ––ȱǻŖǯŜŝŖŝȱ’—ǯǼ
ŵŠ•žŽœȱŠ›Žȱ’—ȱŽ›’Œȱž—’œǯȱŠ•žŽœȱ’—ȱ™Š›Ž—‘ŽœŽœȱŠ›Žȱ—•’œ‘ȱŽšž’ŸŠ•Ž—œǯȱž‹›’ŒŠŽȱ‘›ŽŠœȱ ’‘ȱŽ—’—Žȱ˜’•ȱȱ
ȱ ™›’˜›ȱ˜ȱŠœœŽ–‹•¢ǯ
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˜ŸŽ›—˜›ȱ›˜œœȱ‘ŠĞȱ˜›Žȱǯǯ
ȱ Ŝȱ––ȱ‘ŠĞ
ȱ ȱ Ž ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŜǯŖŘśȦŜǯŖśŖȱ––ȱǻŖǯŘřŝŘȦŖǯŘřŞŘȱ’—ǯǼ
ȱ ȱ Š¡ǯȱŽŠ›ȱ’–’ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŜǯŖŜřȱ––ȱǻŖǯŘřŞŝȱ’—ǯǼ
ȱ Şȱ––ȱ‘ŠĞ
ȱ ȱ Ž ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŞǯŖŘśȦŞǯŖŝśȱ––ȱǻŖǯřŗśşȦŖǯřŗŝşȱ’—ǯǼ
ȱ ȱ Š¡ǯȱŽŠ›ȱ’–’ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŞǯŖŞŞȱ––ȱǻŖǯřŗŞŚȱ’—ǯǼ
›ŽŠ‘Ž›ȱ˜ŸŽ›ȱŠœŽ—Ž›ȱ˜›šžŽȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŝǯřȱȉ–ȱǻŜśȱ’—ǯȱ•‹ǯǼ
’•ȱ›Š’—ȱ•žȱ˜›šžŽȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŗřǯŜȱȉ–ȱǻŗŖȱĞǯȱ•‹ǯǼ
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—ȱ•Š¢ȱǻ›ŽŽǼȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŝŖȦŖǯśşŖȱ––ȱǻŖǯŖŖŘŞȦŖǯŖŘřŖȱ’—ǯǼ
—ȱ•Š¢ȱǻ’‘ȱ‘›žœȱŽŠ›’—ȱ˜–™˜—Ž—œǼȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŝŖȦŖǯŘŝŖȱ––ȱǻŖǯŖŖŘŞȦŖǯŖŗŖŖȱ’—ǯǼ
ȱ¡ŒŽ™ȱ
Řśȱ—’—ŽœȱŽ•˜ ȱŽ›’Š•ȱ˜ǯȱŘŚŖřśŖŖŖŖŞȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖśŖȦŖǯŝśŖȱ––ȱǻŖǯŖŖŘŖȦŖǯŖŘşśȱ’—ǯǼ
›Š—”œ‘ŠĞȱ˜›Žȱǻ—ȱ›Š—”ŒŠœŽǼ
ȱ ȱ Ž ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŚŖǯşŜśȦŚŗǯŖŖřȱ––ȱǻŗǯŜŗŘŞȦŗǯŜŗŚřȱ’—ǯǼ
ȱ ȱ Š¡ǯȱŽŠ›ȱ’–’ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŚŗǯŖŗŜȱ––ȱǻŗǯŜŗŚŞȱ’—ǯǼ
›Š—”œ‘ŠĞȱ˜ȱ•ŽŽŸŽȱŽŠ›’—ȱǻ›Š—”ŒŠœŽǼ
ȱ ȱ ž——’—ȱ•ŽŠ›Š—ŒŽȱȬȱŽ ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖřȦŖǯŖşȱ––ȱǻŖǯŖŖŗŘȦŖǯŖŖřśȱ’—ǯǼ
›Š—”œ‘ŠĞȱ˜›Žȱǻ—ȱ•˜œž›Žȱ•ŠŽǼȱȬȱŽ ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŚŖǯşŞŝȦŚŖǯşŝŚȱ––ȱǻŗǯŜŗřŜȦŗǯŜŗřŗȱ’—ǯǼ
›Š—”œ‘ŠĞȱ˜›Žȱǻ—ȱ•˜œž›Žȱ•ŠŽǼȬ˜Ȭ›Š—”œ‘ŠĞ
ȱ ȱ ž——’—ȱ•ŽŠ›Š—ŒŽȱȬȱŽ ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖřşȦŖǯŖŝŚȱ––ȱǻŖǯŖŖŗśȦŖǯŖŖŘşȱ’—ǯǼ
•¢ ‘ŽŽ•ȱ—ȱŠ’—ȱŽŠ›’—ȱ˜ž›—Š•
ȱ ȱ ǯǯȱȬȱŽ ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŚŖǯşŗřȦŚŖǯşřśȱ––ȱǻŗǯŜŗŖŝȦŗǯŜŗŗŜȱ’—ǯǼ
ȱ ȱ ǯǯȱȬȱŠ¡ǯȱŽŠ›ȱ’–’ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŚŖǯŞŚȱ––ȱǻŗǯŜŖŞȱ’—ǯǼ
ȱ ȱ Š¡ǯȱŠ™Ž›ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŘŘȱ––ȱǻŖǯŖŖŖşȱ’—ǯǼ
ȱ ȱ Š¡ǯȱžȬ˜Ȭ˜ž—ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŘśȱ––ȱǻŖǯŖŖŗŖȱ’—ǯǼ
•˜œž›Žȱ•ŠŽȱ—ȱŠ’—ȱŽŠ›’—ȱ˜ž›—Š•
ȱ ȱ ǯǯȱȬȱŽ ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŚŖǯşŗřȦŚŖǯşřśȱ––ȱǻŗǯŜŗŖŝȦŗǯŜŗŗŜȱ’—ǯǼ
ȱ ȱ ǯǯȱȬȱŠ¡ǯȱŽŠ›ȱ’–’ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŚŖǯŞŚȱ––ȱǻŗǯŜŖŞȱ’—ǯǼ
ȱ ȱ Š¡ǯȱŠ™Ž›ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŘŘȱ––ȱǻŖǯŖŖŖşȱ’—ǯǼ
ȱ ȱ Š¡ǯȱžȬ˜Ȭ˜ž—ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŘśȱ––ȱǻŖǯŖŖŗŖȱ’—ǯǼ
˜——ŽŒ’—ȱ˜ȱ˜ž›—Š•
ȱ ȱ ǯǯȱȬȱŽ ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯřśǯşśśȦřśǯşŝřȱ––ȱǻŗǯŚŗśŜȦŗǯŚŗŜřȱ’—ǯǼ
ȱ ȱ ǯǯȱȬȱŠ¡ǯȱŽŠ›ȱ’–’ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯřśǯşŚȱ––ȱǻŗǯŚŗśȱ’—ǯǼ
ȱ ȱ Š¡ǯȱŠ™Ž›ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŗŞȱ––ȱǻŖǯŖŖŖŝȱ’—ǯǼ
ȱ ȱ Š¡ǯȱžȬ˜Ȭ˜ž—ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŘśȱ––ȱǻŖǯŖŖŗŖȱ’—ǯǼ
Section 1
Safety and General Information
Crankshaft cont.
Crankshaft T.I.R.
PTO End, Crank in Engine..............................................................................0.279 mm (0.0110 in.)
Entire Crank, in V-Blocks................................................................................0.10 mm (0.0039 in.)
1
Cylinder Bore
Cylinder Bore I.D.
New
CH18/CH620,CH20/CH640,CH22 (624 cc)....................................................77.000/77.025 mm (3.0315/3.0325 in.)
CH22/CH670,CH23/CH680 (674 cc)...............................................................80.000/80.025 mm (3.1496/3.1506 in.)
CH25,CH26/CH735,CH730,CH740,CH745,CH750......................................82.988/83.013 mm (3.2672/3.2682 in.)
Max. Wear Limit-CH18/CH620,CH20/CH640,CH22 (624 cc).....................77.063 mm (3.0340 in.)
Max. Wear Limit-CH22/CH670,CH23/CH680 (674 cc)................................80.065 mm (3.1522 in.)
Max. Wear Limit-CH25,CH26/CH735,CH730,CH740,CH745,CH750.......83.051 mm (3.2697 in.)
Max. Out-of-Round..........................................................................................0.12 mm (0.0047 in.)
Max. Taper.........................................................................................................0.05 mm (0.0020 in.)
Cylinder Head
Cylinder Head Fastener Torque
Hex Flange Nut - Torque in Two Stages........................................................first to 16.9 N·m (150 in. lb.)
finally to 33.9 N·m (300 in. lb.)
Head Bolt - Torque in Two Stages..................................................................first to 22.6 N·m (200 in. lb.)
finally to 41.8 N·m (370 in. lb.)
Max. Out-of-Flatness................................................................................................0.076 mm (0.003 in.)
Rocker Arm Screw Torque.......................................................................................11.3 N·m (100 in. lb.)
Fan/Flywheel
Fan Fastener Torque.................................................................................................9.9 N·m (88 in. lb.)
Flywheel Retaining Screw Torque..........................................................................66.4 N·m (49 ft. lb.)
Governor
Governor Cross Shaft-to-Crankcase Running Clearance
6 mm Shaft...............................................................................................................0.013/0.075 mm (0.0005/0.0030 in.)
8 mm Shaft...............................................................................................................0.025/0.126 mm (0.0009/0.0049 in.)
Governor Cross Shaft O.D.
6 mm Shaft
New.....................................................................................................................5.975/6.012 mm (0.2352/0.2367 in.)
Max. Wear Limit...............................................................................................5.962 mm (0.2347 in.)
8 mm Shaft
New.....................................................................................................................7.949/8.000 mm (0.3129/0.3149 in.)
Max. Wear Limit...............................................................................................7.936 mm (0.3124 in.)
Governor Gear Shaft-to-Governor Gear Running Clearance.............................0.015/0.140 mm (0.0006/0.0055 in.)
Governor Gear Shaft O.D.
New.....................................................................................................................5.990/6.000 mm (0.2358/0.2362 in.)
Max. Wear Limit...............................................................................................5.977 mm (0.2353 in.)
Governor Lever Nut Torque....................................................................................6.8 N·m (60 in. lb.)
1.11
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—’’˜—ȱ˜ž•ŽȱŠœŽ—Ž›ȱ˜›šžŽȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŚǯŖȬŜǯŘȱȉ–ȱǻřśȬśśȱ’—ǯȱ•‹ǯǼ
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žĝŽ›ȱŽŠ’—’—ȱžȱ˜›šžŽǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŘŚǯŚȱȉ–ȱǻŘŗŜȱ’—ǯȱ•‹ǯǼ
2LO)LOWHU
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ȱ ȱ Ž ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŗŝǯŖŖŜȦŗŝǯŖŗŘȱ––ȱǻŖǯŜŜşśȦŖǯŜŜşŞȱ’—ǯǼ
ȱ ȱ Š¡ǯȱŽŠ›ȱ’–’ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŗŝǯŖŘśȱ––ȱǻŖǯŜŝŖřȱ’—ǯǼ
’œ˜—ȱ’—ȱǯǯ
ȱ ȱ Ž ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŗŜǯşşśȦŗŝǯŖŖŖȱ––ȱǻŖǯŜŜşŗȦŖǯŜŜşřȱ’—ǯǼ
ȱ ȱ Š¡ǯȱŽŠ›ȱ’–’ȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŗŜǯşşŚȱ––ȱǻŖǯŜŜşŗȱ’—ǯǼ
˜™ȱ˜–™›Žœœ’˜—ȱ’—Ȭ˜Ȭ›˜˜ŸŽȱ’Žȱ•ŽŠ›Š—ŒŽ
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ŜŘŖǰ
ŘŖȦ
ŜŚŖǰ
ŘŘȱǻŜŘŚȱŒŒǼȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŚŖȦŖǯŖŞŖȱ––ȱǻŖǯŖŖŗŜȦŖǯŖŖřŗȱ’—ǯǼ
ȱ ȱ ŘŘȦ
ŜŝŖǰ
ŘřȦ
ŜŞŖȱǻŜŝŚȱŒŒǼȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖřŖȦŖǯŖŝŜȱ––ȱǻŖǯŖŖŗŘȦŖǯŖŖřŖȱ’—ǯǼ
ȱ ȱ Řśǰ
ŘŜȦ
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ŝśŖȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŘśȦŖǯŖŚŞȱ––ȱǻŖǯŖŖŗŖȦŖǯŖŖŗşȱ’—ǯǼ
’•Žȱ˜–™›Žœœ’˜—ȱ’—Ȭ˜Ȭ›˜˜ŸŽȱ’Žȱ•ŽŠ›Š—ŒŽ
ȱ ȱ ŗŞȦ
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ŘŘȱǻŜŘŚȱŒŒǼȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŚŖȦŖǯŖŞŖȱ––ȱǻŖǯŖŖŗŜȦŖǯŖŖřŗȱ’—ǯǼ
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ŜŞŖȱǻŜŝŚȱŒŒǼȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖřŖȦŖǯŖŝŜȱ––ȱǻŖǯŖŖŗŘȦŖǯŖŖřŖȱ’—ǯǼ
ȱ ȱ Řśǰ
ŘŜȦ
ŝřśǰ
ŝřŖǰ
ŝŚŖǰ
ŝŚśǰ
ŝśŖȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŗśȦŖǯŖřŝȱ––ȱǻŖǯŖŖŖŜȦŖǯŖŖŗśȱ’—ǯǼ
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ȱ ȱ ŗŞȦ
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ŘŘȱǻŜŘŚȱŒŒǼȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŜŖȦŖǯŘŖŘȱ––ȱǻŖǯŖŖŘŚȦŖǯŖŖŞŖȱ’—ǯǼ
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ŜŝŖǰ
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ŝśŖȱǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯǯŖǯŖŘŜȦŖǯŗŝŜȱ––ȱǻŖǯŖŖŗŖȦŖǯŖŖŝŖȱ’—ǯǼ
Section 1
Safety and General Information
Piston, Piston Rings, and Piston Pin cont.
Top and Center Compression Ring End Gap
New Bore
CH18/CH620,CH20/CH640,CH22 (624 cc)....................................................0.25/0.45 mm (0.0098/0.0177 in.)
CH22/CH670,CH23/CH680 (674 cc)...............................................................0.18/0.46 mm (0.0071/0.0181 in.)
CH25,CH26/CH735,CH730,CH740,CH745...................................................0.25/0.56 mm (0.0100/0.0224 in.)
Used Bore (Max)
CH18/CH620,CH20/CH640,CH22 (624 cc)....................................................0.77 mm (0.030 in.)
CH22/CH670,CH23/CH680 (674 cc)...............................................................0.80 mm (0.0315 in.)
CH25,CH26/CH735,CH730,CH740,CH745,CH750 . ...................................0.94 mm (0.037 in.)
1
Piston Thrust Face O.D.²
New
CH18/CH620,CH20/CH640,CH22 (624 cc)....................................................76.967/76.985 mm (3.0302/3.0309 in.)
CH22/CH670,CH23/CH680 (674 cc)...............................................................79.963/79.979 mm (3.1481/3.1488 in.)
CH25,CH26/CH735,CH730,CH740,CH745,CH750......................................82.986 mm (3.2671 in.)
Max. Wear Limit
CH18/CH620,CH20/CH640,CH22 (624 cc)....................................................76.840 mm (3.0252 in.)
CH22/CH670 (674 cc).......................................................................................79.831 mm (3.1430 in.)
CH25,CH26/CH735,CH730,CH740,CH745,CH750......................................82.841 mm (3.2614 in.)
Piston Thrust Face-to-Cylinder Bore² Running Clearance
New
CH18/CH620,CH20/CH640,CH22 (624 cc)....................................................0.014/0.057 mm (0.0005/0.0022 in.)
CH22/CH670,CH23/CH680 (674 cc)...............................................................0.021/0.062 mm (0.0008/0.0024 in.)
CH25,CH26/CH735,CH730,CH740,CH745,CH750......................................0.001/0.045 mm (0.039/0.0018 in.)
Speed Control Bracket
Fastener Torque.........................................................................................................10.7 N·m (95 in. lb.) into new holes
7.3 N·m (65 in. lb.) into used holes
Starter Assembly
Thru Bolt Torque
UTE/Johnson Electric, Eaton (Inertia Drive).................................................4.5-5.7 N·m (40-50 in. lb.)
Nippondenso (Solenoid Shift)........................................................................4.5-7.5 N·m (40-84 in. lb.)
Delco-Remy (Solenoid Shift)...........................................................................5.6-9.0 N·m (49-79 in. lb.)
Mounting Screw Torque (All).................................................................................15.3 N·m (135 in. lb.)
Brush Holder Mounting Screw Torque
Delco-Remy Starter...........................................................................................2.5-3.3 N·m (22-29 in. lb.)
Solenoid (Starter)
Mounting Hardware Torque
Nippondenso Starter........................................................................................6.0-9.0 N·m (53-79 in. lb.)
Delco-Remy Starter...........................................................................................4.0-6.0 N·m (35-53 in. lb.)
Nut, Positive (+) Brush Lead Torque
Nippondenso Starter........................................................................................8.0-12.0 N·m (71-106 in. lb.)
Delco-Remy Starter...........................................................................................8.0-11.0 N·m (71-97 in. lb.)
Stator
Mounting Screw Torque...........................................................................................6.2 N·m (55 in. lb.)
²Measure 6 mm (0.236 in.) above the bottom of the piston skirt at right angles to the piston pin.
1.13
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Section 2
Tools & Aids
Section 2
Tools & Aids
2
Certain quality tools are designed to help you perform specific disassembly, repair, and reassembly procedures.
By using tools designed for the job, you can properly service engines easier, faster, and safer! In addition, you’ll
increase your service capabilities and customer satisfaction by decreasing engine downtime.
Here is the list of tools and their source.
Separate Tool Suppliers:
Kohler Tools
Contact your source
of supply.
SE Tools
415 Howard St.
Lapeer, MI 48446
Phone 810-664-2981
Toll Free 800-664-2981
Fax 810-664-8181
Design Technology Inc.
768 Burr Oak Drive
Westmont, IL 60559
Phone 630-920-1300
Tools
Description
Source/Part No.
Balance Gear Tim ing Tool (K & M Ser ies)
To hold balance gears in timed position when assembling engine.
Kohler 25 455 06-S
(Formerly Y-357)
Cam shaft Endplay Plat e
For checking camshaft endplay.
S E Tools KLR-82405
Cylinder Leakdow n Test er
For checking combustion retention and if cylinder, piston, rings, or valves are worn.
Kohler 25 761 05-S
Elect r onic Fuel Inject ion (EFI) Diagnost ic Soft w ar e
U se with Laptop or Desktop PC.
EFI Ser vice Kit
For troubleshooting and setting up an EFI engine.
Individual Components Available
Pressure Tester
Noid Light
90° Adapter
Oetiker Clamp Pliers
Code Plug, Red Wire
Code Plug, Blue Wire
Kohler 25 761 23-S
Kohler 24 761 01-S
Design Technology Inc.
DTI-019
DTI-021
DTI-023
DTI-025
DTI-027
DTI-029
Flyw heel Holding Tool (CS Ser ies)
S E Tools KLR-82407
Flyw heel Puller
To remove flywheel from engine.
S E Tools KLR-82408
2.1
Section 2
Tools & Aids
Tools (cont.)
Description
Source/Part No.
Flyw heel St r ap Wr ench
To hold flywheel during removal.
S E Tools KLR-82409
Hydr aulic Valve Lift er Tool
To remove and install hydraulic lifters.
Kohler 25 761 38-S
Ignit ion Syst em Test er
For testing output on all systems, except CD.
For testing output on capacitive discharge (CD) ignition system.
Kohler 25 455 01-S
Kohler 24 455 02-S
Offset Wr ench (K & M Ser ies)
To remove and reinstall cylinder barrel retaining nuts.
S E Tools KLR-82410
Oil Pr essur e Test Kit
To test and verify oil pressure.
Kohler 25 761 06-S
Rect ifier -Regulat or Test er (120 volt cur r ent )
Rect ifier -Regulat or Test er (240 volt cur r ent )
U sed to test rectifier-regulators.
Kohler 25 761 20-S
Kohler 25 761 41-S
Individual Components Available
CS -PRO Regulator Test Harness
S pecial Regulator Test Harness with Diode
Design Technology Inc.
DTI-031
DTI-033
Spar k Advance Module (SAM) Test er
To test the S AM (AS AM and DS AM) on engines with S MART-S PARK™.
Kohler 25 761 40-S
St ar t er Br ush Holding Tool (Solenoid Shift )
To hold brushes during servicing.
S E Tools KLR-82416
St ar t er Ret aining Ring Tool (Iner t ia Dr ive)
To remove and reinstall drive retaining rings (excluding FAS CO starters).
Kohler 25 761 18-S
St ar t er Ser vicing Kit (All St ar t er s)
To remove and reinstall drive retaining rings and brushes.
S E Tools KLR-82411
Individual Component Available
S tarter Brush Holding Tool (S olenoid S hift)
Tachom et er (Digit al Induct ive)
For checking operating speed (RPM) of an engine.
S E Tools KLR-82416
Design Technology Inc.
DTI-110
Vacuum /Pr essur e Test er
Alternative to a water manometer.
Kohler 25 761 22-S
Valve Guide Ream er (K & M Ser ies)
For sizing valve guides after installation.
S E Tools KLR-82413
Valve Guide Ser vice Kit (Cour age, Aegis, Com m and, OHC)
For servicing worn value guides.
S E Tools KLR-82415
2.2
Section 2
Tools & Aids
Aids
Description
Source/Part No.
Cam shaft Lubr icant (Valspar ZZ613)
Kohler 25 357 14-S
Dielect r ic Gr ease (GE/Novaguard G661)
Kohler 25 357 11-S
Dielect r ic Gr ease (Fel-Pro)
Lubri-S el
Elect r ic St ar t er Dr ive Lubr icant (Inertia Drive)
Kohler 52 357 01-S
Elect r ic St ar t er Dr ive Lubr icant (S olenoid S hift)
Kohler 52 357 02-S
RTV Silicone Sealant
Loctite® 5900 Heavy Body in 4 oz aerosol dispenser.
Kohler 25 597 07-S
Only oxime-based, oil resistant RTV sealants, such as those listed, are approved for use.
Loctite® Nos. 5900 or 5910 are recommended for best sealing characteristics.
Loctite®
Loctite®
Loctite®
Loctite®
5910
U ltra Black 598
U ltra Blue 587
U ltra Copper
Spline Dr ive Lubr icant
Kohler 25 357 12-S
2.3
2
Section 2
Tools & Aids
Special Tools You Can Make
Flywheel Holding Tool
A flywheel holding tool can be made out of an old
junk flywheel ring gear as shown in Figure 2-1, and
used in place of a strap wrench.
1. Using an abrasive cut-off wheel, cut out a six
tooth segment of the ring gear as shown.
2. Grind off any burrs or sharp edges.
3. Invert the segment and place it between the
ignition bosses on the crankcase so that the tool
teeth engage the flywheel ring gear teeth. The
bosses will lock the tool and flywheel in
position for loosening, tightening or removing
with a puller.
2. Remove the studs of a Posi-Lock rod or grind off
the aligning steps of a Command rod, so the joint
surface is flat.
3. Find a 1 in. long capscrew with the correct
thread size to match the threads in the
connecting rod.
4. Use a flat washer with the correct I.D. to slip on
the capscrew and approximately 1” O.D. (Kohler
Part No. 12 468 05-S). Assemble the capscrew
and washer to the joint surface of the rod, as
shown in Figure 2-2.
Figure 2-2. Rocker Arm/Crankshaft Tool.
Figure 2-1. Flywheel Holding Tool.
Rocker Arm/Crankshaft Tool
A spanner wrench to lift the rocker arms or turn the
crankshaft may be made out of an old junk connecting
rod.
1. Find a used connecting rod from a 10 HP or
larger engine. Remove and discard the rod cap.
2.4
Section 3
Troubleshooting
Section 3
Troubleshooting
Troubleshooting Guide
When troubles occur, be sure to check the simple
causes which, at first, may seem too obvious to be
considered. For example, a starting problem could be
caused by an empty fuel tank.
Some general common causes of engine troubles are
listed below. Use these to locate the causing factors.
Refer to the specific section(s) within this service
manual for more detailed information.
Engine Cranks But Will Not Start
1. Empty fuel tank.
2. Fuel shut-off valve closed.
3. Poor fuel, dirt or water in the fuel system.
4. Clogged fuel line.
5. Spark plug lead(s) disconnected.
6. Key switch or kill switch in “off” position.
7. Faulty spark plugs.
8. Faulty ignition module(s).
9. SMART-SPARK™ malfunction (applicable models).
10. Carburetor solenoid malfunction.
11. Diode in wiring harness failed in open circuit
mode.
12. Vacuum fuel pump malfunction, or oil in vacuum
hose.
13. Vacuum hose to fuel pump leaking/cracked.
14. Battery connected backwards.
15. Safety interlock system engaged.
Engine Starts But Does Not Keep Running
1. Restricted fuel tank cap vent.
2. Poor fuel, dirt or water in the fuel system.
3. Faulty or misadjusted choke or throttle controls.
4. Loose wires or connections that short the kill
terminal of ignition module to ground.
5. Faulty cylinder head gasket.
6. Faulty carburetor.
7. Vacuum fuel pump malfunction, or oil in vacuum
hose.
8. Leaking/cracked vacuum hose to fuel pump.
9. Intake system leak.
3
10. Diode in wiring harness failed in open circuit
mode.
Engine Starts Hard
1. PTO drive is engaged.
2. Dirt or water in the fuel system.
3. Clogged fuel line.
4. Loose or faulty wires or connections.
5. Faulty or misadjusted choke or throttle controls.
6. Faulty spark plugs.
7. Low compression.
8. Weak spark.
9. Fuel pump malfunction causing lack of fuel.
10. Engine overheated-cooling/air circulation
restricted.
11. Quality of fuel.
12. Flywheel key sheared.
13. Intake system leak.
Engine Will Not Crank
1. PTO drive is engaged.
2. Battery is discharged.
3. Safety interlock switch is engaged.
4. Loose or faulty wires or connections.
5. Faulty key switch or ignition switch.
6. Faulty electric starter or solenoid.
7. Seized internal engine components.
Engine Runs But Misses
1. Dirt or water in the fuel system.
2. Spark plug lead disconnected.
3. Poor quality of fuel.
4. Faulty spark plug(s).
5. Loose wires or connections that intermittently
ground the ignition kill circuit.
6. Engine overheated.
7. Faulty ignition module or incorrect air gap.
8. Carburetor adjusted incorrectly.
9. SMART-SPARK™ malfunction (applicable
models).
3.1
Section 3
Troubleshooting
Engine Will Not Idle
1. Dirt or water in the fuel system.
2. Stale fuel and/or gum in carburetor.
3. Faulty spark plugs.
4. Fuel supply inadequate.
5. Idle speed adjusting screw improperly set.
6. Idle fuel adjusting needle improperly set (some
models).
7. Low compression.
8. Restricted fuel tank cap vent.
9. Engine overheated-cooling system/air circulation
problem.
Engine Overheats
1. Air intake/grass screen, cooling fins, or cooling
shrouds clogged.
2. Excessive engine load.
3. Low crankcase oil level.
4. High crankcase oil level.
5. Faulty carburetor.
6. Lean fuel mixture.
7. SMART-SPARK™ malfunction (applicable
models).
Engine Knocks
1. Excessive engine load.
2. Low crankcase oil level.
3. Old or improper fuel.
4. Internal wear or damage.
5. Hydraulic lifter malfunction.
6. Quality of fuel.
7. Incorrect grade of oil.
Engine Loses Power
1. Low crankcase oil level.
2. High crankcase oil level.
3. Dirty air cleaner element.
4. Dirt or water in the fuel system.
5. Excessive engine load.
6. Engine overheated.
7. Faulty spark plugs.
8. Low compression.
9. Exhaust restriction.
10. SMART-SPARK™ malfunction (applicable
models).
11. Low battery.
12. Incorrect governor setting.
Engine Uses Excessive Amount of Oil
1. Incorrect oil viscosity/type.
2. Clogged or improperly assembled breather.
3. Breather reed broken.
4. Worn or broken piston rings.
5. Worn cylinder bore.
6. Worn valve stems/valve guides.
7. Crankcase overfilled.
8. Blown head gasket/overheated.
Oil Leaks from Oil Seals, Gaskets
1. Crankcase breather is clogged or inoperative.
2. Breather reed broken.
3. Loose or improperly torqued fasteners.
4. Piston blowby or leaky valves.
5. Restricted exhaust.
External Engine Inspection
Before cleaning or disassembling the engine, make a
thorough inspection of its external appearance and
condition. This inspection can give clues to what
might be found inside the engine (and the cause)
when it is disassembled.
• Check for buildup of dirt and debris on the
crankcase, cooling fins, grass screen, and other
external surfaces. Dirt or debris on these areas
are causes of higher operating temperatures and
overheating.
• Check for obvious fuel and oil leaks, and
damaged components. Excessive oil leakage can
indicate a clogged or improperly-assembled
breather, worn/damaged seals and gaskets, or
loose or improperly-torqued fasteners.
• Check the air cleaner cover and base for damage
or indications of improper fit and seal.
• Check the air cleaner element. Look for holes,
tears, cracked or damaged sealing surfaces, or
other damage that could allow unfiltered air into
the engine. Also note if the element is dirty or
clogged. These could indicate that the engine has
been under serviced.
• Check the carburetor throat for dirt. Dirt in the
throat is further indication that the air cleaner is
not functioning properly.
• Check the oil level. Note if the oil level is within
the operating range on the dipstick, or if it is low
or overfilled.
3.2
Section 3
Troubleshooting
• Check the condition of the oil. Drain the oil into a
container - the oil should flow freely. Check for
metal chips and other foreign particles.
Sludge is a natural by-product of combustion; a
small accumulation is normal. Excessive sludge
formation could indicate overrich carburetion,
weak ignition, overextended oil change interval
or wrong weight or type of oil was used, to name
a few.
NOTE: It is good practice to drain oil at a
location away from the workbench. Be
sure to allow ample time for complete
drainage.
To test the crankcase vacuum with the manometer:
1. Insert the stopper/hose into the oil fill hole. Leave
the other tube of manometer open to
atmosphere. Make sure the shut off clamp is
closed.
2. Start the engine and run at no-load high speed
(3200 to 3750 RPM).
3. Open the clamp and note the water level in the
tube.
The level in the engine side should be a
minimum of 10.2 cm (4 in.) above the level in the
open side.
Cleaning the Engine
After inspecting the external condition of the engine,
clean the engine thoroughly before disassembling it.
Also clean individual components as the engine is
disassembled. Only clean parts can be accurately
inspected and gauged for wear or damage. There are
many commercially available cleaners that will
quickly remove grease, oil, and grime from engine
parts. When such a cleaner is used, follow the
manufacturer’s instructions and safety precautions carefully.
Make sure all traces of the cleaner are removed before
the engine is reassembled and placed into operation.
Even small amounts of these cleaners can quickly
break down the lubricating properties of engine oil.
Basic Engine Tests
Crankcase Vacuum Test
A partial vacuum should be present in the crankcase
when the engine is operating. Pressure in the
crankcase (normally caused by a clogged or
improperly assembled breather) can cause oil to be
forced out at oil seals, gaskets, or other available
spots.
Crankcase vacuum is best measured with either a
water manometer or a vacuum gauge (see Section 2).
Complete instructions are provided in the kits.
If the level in the engine side is less than specified
(low/no vacuum), or the level in the engine side
is lower than the level in the open side
(pressure), check for the conditions in the table
on page 3.4.
4. Close the shut off clamp before stopping the
engine.
To test the crankcase vacuum with the Vacuum/
Pressure Gauge Kit (see Section 2):
1. Remove the dipstick or oil fill plug/cap.
2. Install the adapter into the oil fill/dipstick tube
opening, upside down over the end of a small
diameter dipstick tube, or directly into engine if
a tube is not used.
3. Push the barbed fitting on the gauge solidly into
the hole in the adapter.
4. Start the engine and bring it up to operating
speed (3200-3600 RPM).
5. Check the reading on the gauge. If the reading is
to the left of “0” on the gauge, vacuum or
negative pressure is indicated. If the reading is to
the right of “0” on the gauge, positive pressure is
present.
Crankcase vacuum should be 4-10 (inches of
water) If the reading is below specification, or if
pressure is present, check the following table for
possible causes and remedies.
3.3
3
Section 3
Troubleshooting
No Crankcase Vacuum/Pressure in Crankcase
Possible Cause
Solution
1. Crankcase breather clogged or inoperative.
1. Disassemble breather, clean parts thoroughly,
check sealing surfaces for flatness, reassemble,
and recheck pressure.
2. Seals and/or gaskets leaking. Loose or
improperly torqued fasteners.
2. Replace all worn or damaged seals and gaskets.
Make sure all fasteners are tightened securely.
Use appropriate torque values and sequences
when necessary.
3. Piston blowby or leaky valves (confirm by
inspecting components).
3. Recondition piston, rings, cylinder bore, valves,
and valve guides.
4. Restricted exhaust.
4. Repair/replace restricted muffler/exhaust
system.
Compression Test
Some of these engines are equipped with an automatic
compression release (ACR) mechanism. Because of the
ACR mechanism, it is difficult to obtain an accurate
compression reading. As an alternative, perform a
cylinder leakdown test.
Cylinder Leakdown Test
A cylinder leakdown test can be a valuable
alternative to a compression test. By pressurizing the
combustion chamber from an external air source you
can determine if the valves or rings are leaking, and
how badly.
Cylinder Leakdown Tester (see Section 2) is a
relatively simple, inexpensive leakdown tester for
small engines. The tester includes a quick disconnect
for attaching the adapter hose, and a holding tool.
Leakdown Test Instructions
1. Run engine for 3-5 minutes to warm it up.
2. Remove spark plug(s) and air filter from engine.
3. Rotate the crankshaft until the piston (of cylinder
being tested) is at top dead center of the
compression stroke. Hold the engine in this
position while testing. The holding tool supplied
with the tester can be used if the PTO end of the
crankshaft is accessible. Lock the holding tool
onto the crankshaft. Install a 3/8" breaker bar
into the hole/slot of the holding tool, so it is
perpendicular to both the holding tool and
crankshaft PTO.
3.4
If the flywheel end is more accessible, use a
breaker bar and socket on the flywheel nut/
screw to hold it in position. An assistant may be
needed to hold the breaker bar during testing. If
the engine is mounted in a piece of equipment, it
may be possible to hold it by clamping or
wedging a driven component. Just be certain that
the engine cannot rotate off of TDC in either
direction.
4. Install the adapter into the spark plug hole, but
do not attach it to the tester at this time.
5. Connect an air source of at least 50 psi to the
tester.
6. Turn the regulator knob in the increase
(clockwise) direction until the gauge needle is in
the yellow “set” area at the low end of the scale.
7. Connect the tester quick-disconnect to the
adapter hose while firmly holding the engine at
TDC. Note the gauge reading and listen for
escaping air at the carburetor intake, exhaust
outlet, and crankcase breather.
8. Check your test results against the following
table:
Section 3
Troubleshooting
Leakdown Test Results
Air escaping from crankcase breather ........................................................ Defective rings or worn cylinder.
Air escaping from exhaust system .............................................................. Defective exhaust valve/improper seating.
Air escaping from carburetor ....................................................................... Defective intake valve/improper seating.
Gauge reading in “low” (green) zone .......................................................... Piston rings and cylinder in good
condition.
Gauge reading in “moderate” (yellow) zone .............................................. Engine is still usable, but there is some
wear present. Customer should start
planning for overhaul or replacement.
Gauge reading in “high” (red) zone ............................................................. Rings and/or cylinder have considerable
wear. Engine should be reconditioned or
replaced.
3.5
3
Section 3
Troubleshooting
3.6
Section 4
Air Cleaner and Air Intake System
Air Cleaners
General
Most engines are equipped with a replaceable, highdensity paper air cleaner element, surrounded by an
oiled foam precleaner, and housed under a flat outer
cover. This is typically referred to as the standard air
cleaner assembly. See Figures 4-1 and 4-4. Some
engines utilize a heavy-duty style air cleaner as shown
in Figure 4-12.
4
Figure 4-2. Removing Latch Style Cover.
Cover
Air Cleaner Element
Figure 4-1. Standard Air Cleaner.
Precleaner
Standard Air Cleaner
Service
Check the air cleaner daily or before starting the
engine. Check for and correct any buildup of dirt and
debris, along with loose or damaged components.
NOTE: Operating the engine with loose or damaged
air cleaner components could allow
unfiltered air into the engine, causing
premature wear and failure.
Figure 4-3. Removing Knob Style Cover.
Precleaner Service
If so equipped, wash and reoil the precleaner every 25
hours of operation (more often under extremely dusty
or dirty conditions).
To service the precleaner, perform the following steps:
1. Unhook the latches or loosen the retaining knob,
and remove the cover.
2. Remove the foam precleaner from the paper air
cleaner element.
4.1
Section 4
Air Cleaner and Air Intake System
3. Wash the precleaner in warm water with
detergent. Rinse the precleaner thoroughly until
all traces of detergent are eliminated. Squeeze out
excess water (do not wring). Allow the precleaner
to air dry.
4. Saturate the precleaner with new engine oil.
Squeeze out all excess oil.
Seal
5. Reinstall the precleaner over the paper air cleaner
element.
6. Reinstall the air cleaner cover. Secure the cover
with the two latches or the retaining knob.
Element Cover
Figure 4-6. Removing Elements.
Wing Nut
Precleaner
Element
Figure 4-4. Air Cleaner Components.
Figure 4-7. Removing Rubber Seal from Bracket.
Paper Element Service (Standard Type)
Every 100 hours of operation (more often under
extremely dusty or dirty conditions), replace the paper
element. Follow these steps:
1. Unhook the latches or loosen the retaining knob,
and remove the cover.
2. Remove the wing nut, element cover, and paper
element with precleaner (if so equipped).
Figure 4-5. Removing Element Cover Wing Nut.
3. Remove the precleaner (if so equipped) from the
paper element. Service the precleaner as
described in "Precleaner Service".
4. Do not wash the paper element or use
pressurized air, as this will damage the element.
Replace a dirty, bent, or damaged element with a
genuine Kohler element. Handle new elements
carefully; do not use if the sealing surfaces are
bent or damaged.
4.2
Section 4
Air Cleaner and Air Intake System
5. Check the seal for any damage or deterioration.
Replace as necessary. See Figure 4-7.
6. Reinstall the seal, paper element, precleaner,
element cover, and wing nut.
7. Reinstall the air cleaner cover and secure with the
latches or the retaining knob.
NOTE: Make sure the correct depth air cleaner
element and rubber seal are used for the
engine spec involved. Some engines use
a deeper or extra capacity air cleaner and
a longer rubber seal.
4
Figure 4-8. Exploded View of Standard Air Intake System Components.
4.3
Section 4
Air Cleaner and Air Intake System
Air Cleaner Element Cover and Seal - Make sure
element cover is not bent or damaged. Make sure the
wing nut and seal are in place to ensure the element is
sealed against leakage.
Air Cleaner Base - Make sure the base is secured
tightly to the carburetor and not cracked or damaged.
Breather Tube - Make sure the tube is attached to both
the air cleaner base and the breather cover.
Figure 4-9. Bracket Retaining Screw.
Rear Mounting
Screws
NOTE: Damaged, worn or loose air cleaner
components can allow unfiltered air into the
engine causing premature wear and failure.
Tighten or replace all loose or damaged
components.
Complete Disassembly and Reassembly Standard Type
If the base plate on the standard type has to be
removed, proceed as follows:
1. Remove air cleaner components as described
earlier.
2. Remove the hex flange screws securing the
bracket and base. See Figures 4-9 and 4-10.
Remove the bracket.
Figure 4-10. Rear Mounting Screws (Used with
Plastic Intake Manifold).
3. Pinch the sealing collar on the breather hose and
push it down through the hole in the air cleaner
base. Carefully feed the upper section of the
breather tube down through the base. See Figure
4-11.
4. Remove the base and gasket.
5. Reverse the procedure to reinstall new or serviced
components. Torque screws to 9.9 N·m (88 in. lb.).
Heavy-Duty Air Cleaner
Figure 4-11. Breather Tube.
Air Cleaner Components
Whenever the air cleaner cover is removed, or the
paper element or precleaner are serviced, check the
following:
4.4
General
The heavy-duty air cleaner consists of a cylindrical
housing, typically mounted to a bracket off the upper
valve cover screws, and connected with a formed
rubber hose to an adapter on the carburetor or throttle
body/intake manifold (EFI units). The air cleaner
housing contains a paper element and inner element,
designed for longer service intervals. The system is
CARB/EPA certified and the components should not be
altered or modified in any way.
Section 4
Air Cleaner and Air Intake System
4. Do not wash the paper element and inner
element or use compressed air, this will damage
the elements. Replace dirty, bent or damaged
elements with new genuine Kohler elements as
required. Handle the new elements carefully; do
not use if the sealing surfaces are bent or
damaged.
5. Check all parts for wear, cracks, or damage.
Replace any damaged components.
Figure 4-12. Heavy-Duty Air Cleaner.
To Service
Every 250 hours of operation (more often under
extremely dusty or dirty conditions), replace the
paper element and check the inner element. Follow
these steps.
1. Unhook the two retaining clips and remove the
end cap from the air cleaner housing.
6. Install the new inner element, followed by the
outer element. Slide each fully into place in the
air cleaner housing.
7. Reinstall the end cap so the dust ejector valve is
down, and secure with the two retaining clips.
See Figure 4-12.
Removal
1. Remove the upper valve cover screws on each
side, securing the main bracket, and loosen the
hose clamp on the adapter inlet, or remove the
adapter mounting screws.
2. Pull the air cleaner element out of the housing.
See Figure 4-13.
2. Lift the entire air cleaner assembly off the engine.
Disassemble or service as required.
Inner
Element
Installation
1. Install the main mounting bracket with the center
section up and the cutout around the carburetor,
aligning the mounting holes with the four upper
valve cover holes.
Element
2. Install and torque the four valve cover mounting
screws to specified torque value.
Figure 4-13. Removing Elements.
3. After the element is removed, check the condition
of the inner element. It should be replaced
whenever it appears dirty, typically every other
time the main element is replaced. Clean the area
around the base of the inner element before
removing it, so dirt does not get into the engine.
3. Reconnect the hose to the adapter and tighten the
clamp, or install a new adapter gasket (if the
adapter was separated from the carburetor), and
torque the mounting fasteners to 7.3 N·m
(65 in. lb.).
NOTE: Adapter configurations may vary
depending on engine and application
involved. Two adapters are shown in
Figure 4-14.
4.5
4
Section 4
Air Cleaner and Air Intake System
*Cleanout kits, Kohler Part No. 25 755 20-S (black) or
25 755 21-S (gold), are recommended to aid
inspection and cleanout of the cooling fins. See
Figure 4-15.
NOTE: Operating the engine with a blocked grass
screen, dirty or plugged cooling fins, and/or
cooling shrouds removed, will cause engine
damage due to overheating.
Figure 4-14. Adapters for Heavy-Duty Air Cleaners.
Air Intake/Cooling System
To ensure proper cooling, make sure the grass screen,
cooling fan fins, and external surfaces of the engine
are kept clean at all times.
Every 100 hours of operation (more often under
extremely dusty or dirty conditions), remove the
blower housing and other cooling shrouds. *Clean the
cooling fins and external surfaces as necessary. Make
sure the cooling shrouds are reinstalled.
4.6
Figure 4-15. Cleanout Kit Installed on Blower
Housing.
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žŽ•ȱ™ž–™ȱǻŽœȱŚǼǯ
ȱ Śǯȱ ‘ŽŒ”ȱ‘Žȱ˜™Ž›Š’˜—ȱ˜ȱžŽ•ȱ™ž–™ǯ
ȱ
Šǯȱ Ž–˜ŸŽȱ‘ŽȱžŽ•ȱ•’—Žȱ›˜–ȱ‘Žȱ’—•ŽȱęĴ’—ȱ˜ȱ
ŒŠ›‹ž›Ž˜›ǯ
ȱ
‹ǯȱ ›Š—”ȱ‘ŽȱŽ—’—ŽȱœŽŸŽ›Š•ȱ’–ŽœȱŠ—ȱ˜‹œŽ›ŸŽȱ
̘ ǯ
ȱ ȱ ȱ‘Ž›Žȱ’œȱ—˜ȱžŽ•ȱŠȱ‘Žȱ’™ȱ˜ȱ‘Žȱœ™Š›”ȱ™•žǰȱ
Œ‘ŽŒ”ȱ˜›ȱžŽ•ȱ̘ ȱ›˜–ȱ‘ŽȱžŽ•ȱŠ—”ȱǻŽœȱřǼǯ
ȱ ȱ ȱžŽ•ȱ˜Žœȱ—˜ȱ̘ ȱ›˜–ȱ‘Žȱ•’—ŽǰȱŒ‘ŽŒ”ȱ‘Žȱ
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œ‘žȬ˜ěȱŸŠ•ŸŽǰȱŠ—ȱžŽ•ȱ•’—Žǯȱ˜››ŽŒȱŠ—¢ȱ˜‹œŽ›ŸŽȱ
™›˜‹•Ž–ȱŠ—ȱ›ŽŒ˜——ŽŒȱ‘Žȱ•’—Žǯ
ȱ Śǯȱ ȱžŽ•ȱ˜Žœȱ̘ ȱ›˜–ȱ‘Žȱ•’—ŽǰȱŒ‘ŽŒ”ȱ˜›ȱŠž•¢ȱ
ŒŠ›‹ž›Ž˜›ǯȱǻŽŽ›ȱ˜ȱ‘ŽȱȈŠ›‹ž›Ž˜›Ȉȱ™˜›’˜—œȱ˜ȱ
‘’œȱœŽŒ’˜—ǯǼ
ȱ ȱ ȱžŽ•ȱ˜Žœȱ—˜ȱ̘ ȱ›˜–ȱ‘Žȱ•’—ŽǰȱŒ‘ŽŒ”ȱ˜›ȱŠȱ
Œ•˜ŽȱžŽ•ȱ•’—Žǯȱȱ‘ŽȱžŽ•ȱ•’—Žȱ’œȱž—˜‹œ›žŒŽǰȱ
Œ‘ŽŒ”ȱ˜›ȱ˜ŸŽ›ę••ŽȱŒ›Š—”ŒŠœŽȱŠ—Ȧ˜›ȱ˜’•ȱ’—ȱ™ž•œŽȱ
•’—Žǯȱȱ—˜—Žȱ˜ȱ‘ŽȱŒ‘ŽŒ”œȱ›ŽŸŽŠ•ȱ‘ŽȱŒŠžœŽȱ˜ȱ‘Žȱ
™›˜‹•Ž–ǰȱ›Ž™•ŠŒŽȱ‘Žȱ™ž–™ǯ
6HFWLRQ
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)XHO3XPS
*HQHUDO
‘ŽœŽȱŽ—’—ŽœȱŠ›ŽȱŽšž’™™Žȱ ’‘ȱŽ’‘Ž›ȱŠȱ™ž•œŽȱ˜›ȱ
–ŽŒ‘Š—’ŒŠ•ȱžŽ•ȱ™ž–™ǯȱŽŽȱ’ž›ŽœȱśȬŗȱŠ—ȱśȬŘǯȱ‘Žȱ
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›˜Œ”Ž›ȱŠ›–ȱ–˜ŸŽ–Ž—ǯȱ‘Žȱ™ž–™’—ȱŠŒ’˜—ȱŒŠžœŽœȱ‘Žȱ
’Š™‘›Š–ȱ˜—ȱ‘Žȱ’—œ’Žȱ˜ȱ‘Žȱ™ž–™ȱ˜ȱ™ž••ȱžŽ•ȱ’—ȱ˜—ȱ
’œȱ˜ — Š›ȱœ›˜”ŽȱŠ—ȱ˜ȱ™žœ‘ȱ’ȱ’—˜ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ
˜—ȱ’œȱž™ Š›ȱœ›˜”Žǯȱ—Ž›—Š•ȱŒ‘ŽŒ”ȱŸŠ•ŸŽœȱ™›ŽŸŽ—ȱ
žŽ•ȱ›˜–ȱ˜’—ȱ‹ŠŒ” Š›ȱ‘›˜ž‘ȱ‘Žȱ™ž–™ǯ
DZȱ —ȱ–˜œȱ–˜Ž•œǰȱ‘Žȱ™ž•œŽȱ•’—Žȱ’œȱ
Œ˜——ŽŒŽȱ˜ȱŠȱęĴ’—ȱ˜—ȱ‘ŽȱŒ›Š—”ŒŠœŽǰȱ
‘’•Žȱ˜—ȱŽŠ›•¢ȱ–˜Ž•œǰȱ’ȱ’œȱŒ˜——ŽŒŽȱ˜ȱ
‘ŽȱŸŠ•ŸŽȱŒ˜ŸŽ›ǯ
ȱ Śǯȱ —œŠ••ȱ‘Žȱ—Ž ȱžŽ•ȱ™ž–™ȱžœ’—ȱ‘Žȱ‘Ž¡ȱ̊—Žȱ
œŒ›Ž œǯȱ˜›šžŽȱ‘Žȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱ˜ȱŘǯřȱȉ–ȱ
ǻŘŖȱ’—ǯȱ•‹ǯǼǯ
DZȱ Š”Žȱœž›Žȱ‘Žȱ˜›’Ž—Š’˜—ȱ˜ȱ‘Žȱ—Ž ȱ
™ž–™ȱ’œȱŒ˜—œ’œŽ—ȱ ’‘ȱ‘Žȱ›Ž–˜ŸŽȱ
™ž–™ǯȱ—Ž›—Š•ȱŠ–ŠŽȱ–Š¢ȱ˜ŒŒž›ȱ’ȱ
’—œŠ••Žȱ’—Œ˜››ŽŒ•¢ǯ
ȱ śǯȱ ˜——ŽŒȱ‘Žȱ™ž•œŽȱ•’—Žȱ˜ȱ‘Žȱ™ž•œŽȱęĴ’—ǯ
2XWOHW/LQHWR&DUEXUHWRU
3XOVH)XHO
3XPS
ȱ Ŝǯȱ ˜——ŽŒȱ‘ŽȱžŽ•ȱ•’—Žœȱ˜ȱ‘Žȱ’—•ŽȱŠ—ȱ˜ž•Žȱ
ęĴ’—œǯ
5HSODFLQJWKH0HFKDQLFDO3XPS
‘Žȱ–ŽŒ‘Š—’ŒŠ•ȱ™ž–™ȱ’œȱŠ—ȱ’—Ž›Š•ȱ™Š›ȱ˜ȱ‘ŽȱŸŠ•ŸŽȱ
Œ˜ŸŽ›ȱŠœœŽ–‹•¢ȱŠ—ȱ—˜ȱœŽ›Ÿ’ŒŽȱœŽ™Š›ŠŽ•¢ǯȱŽŽȱ’ž›Žȱ
śȬŘǯ
3XOVH/LQH
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)LJXUH3XOVH6W\OH)XHO3XPS
3HUIRUPDQFH
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ǻŘȱŠ•ǯȦ‘›ǯǼȱ ’‘ȱŠȱ™›Žœœž›ŽȱŠȱŖǯřȱ™œ’ȱŠ—ȱŠȱžŽ•ȱ•’Ğȱ˜ȱ
ŗŞȱ’—ǯȱ›˜–ȱŒŠ›‹ž›Ž˜›ȱ’—•ŽǯȱȱŗǯřȱȦ‘›ǯȱǻŖǯřŚȱŠ•ǯȦ‘›ǯǼȱ
žŽ•ȱ›ŠŽȱ–žœȱ‹Žȱ–Š’—Š’—ŽȱŠȱśȱ
£ǯ
ȱ ŗǯȱ ’œŒ˜——ŽŒȱ‘ŽȱžŽ•ȱ•’—Žœȱ›˜–ȱ‘Žȱ’—•ŽȱŠ—ȱ˜ž•Žȱ
ęĴ’—œǯ
ȱ Řǯȱ ˜••˜ ȱ‘Žȱ™›˜ŒŽž›Žȱ˜›ȱ›Ž™•ŠŒ’—ȱ‘ŽȱŸŠ•ŸŽȱ
Œ˜ŸŽ›ȱǻŽŒ’˜—œȱşȱŠ—ȱŗŗǼǯ
ȱ řǯȱ ŽŒ˜——ŽŒȱ‘ŽȱžŽ•ȱ•’—Žœȱ˜ȱ‘Žȱ’—•ŽȱŠ—ȱ˜ž•Žȱ
ęĴ’—œǯ
2XWOHW/LQHWR
&DUEXUHWRU
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0HFKDQLFDO
)XHO3XPS
5HSODFLQJWKH3XOVH)XHO3XPS
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œ˜ž›ŒŽȱ˜ȱœž™™•¢ǯȱ˜ȱ›Ž™•ŠŒŽȱ‘Žȱ™ž•œŽȱ™ž–™ȱ˜••˜ ȱ
‘ŽœŽȱœŽ™œDZ
,QOHW/LQH
ȱ ŗǯȱ ’œŒ˜——ŽŒȱ‘ŽȱžŽ•ȱ•’—Žœȱ›˜–ȱ‘Žȱ’—•ŽȱŠ—ȱ˜ž•Žȱ
ęĴ’—œǯ
ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱœŽŒž›’—ȱ‘ŽȱžŽ•ȱ
™ž–™ǯ
)LJXUH0HFKDQLFDO)XHO3XPS
ȱ řǯȱ Ž–˜ŸŽȱ‘Žȱ™ž•œŽȱ•’—Žȱ‘ŠȱŒ˜——ŽŒœȱ‘Žȱ™ž–™ȱ˜ȱ
‘ŽȱŒ›Š—”ŒŠœŽȱ˜›ȱŸŠ•ŸŽȱŒ˜ŸŽ›ǯ
6HFWLRQ
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&DUEXUHWRU
*HQHUDO
—’—Žœȱ’—ȱ‘’œȱœŽ›’ŽœȱŠ›ŽȱŽšž’™™Žȱ ’‘ȱŽ’‘’—ȱ
ę¡Žȱ–Š’—ȱ“ŽȱŒŠ›‹ž›Ž˜›œǯȱ
ŗŞȬŝŚŖȱŽ—’—ŽœȱžœŽȱŠȱ
˜—ŽȬ‹Š››Ž•ȱŒŠ›‹ž›Ž˜›ǯȱ˜œȱŠ™™•’ŒŠ’˜—œȱžœŽȱŠȱžŽ•ȱ
œ‘žȬ˜ěȱœ˜•Ž—˜’ȱ’—œŠ••Žȱ’—ȱ™•ŠŒŽȱ˜ȱ‘ŽȱžŽ•ȱ‹˜ •ȱ
›ŽŠ’—’—ȱœŒ›Ž ǰȱŠ—ȱŠ•œ˜ȱŒ˜—Š’—ȱŠ—ȱŠŒŒŽ•Ž›Š˜›ȱ™ž–™ǯȱ
••ȱŒŠ›‹ž›Ž˜›œȱŽŠž›ŽȱŠȱœŽ•Ȭ›Ž•’ŽŸ’—ȱŒ‘˜”Žȱ•’”Žȱ
˜›ȱœ’–’•Š›ȱ˜ȱ‘Žȱ˜—Žȱœ‘˜ —ȱ’—ȱ‘ŽȱŽ¡™•˜ŽȱŸ’Ž ȱ
˜—ȱ™ŠŽȱśǯŗŖǯȱ
ŝśŖȱŽ—’—ŽœȱžœŽȱŠȱŽ’‘’—ȱȱ ˜Ȭ
‹Š››Ž•ȱŒŠ›‹ž›Ž˜›ȱ˜—ȱŠȱ–ŠŒ‘’—ȱ’—Š”Žȱ–Š—’˜•ǯȱ‘’œȱ
ŒŠ›‹ž›Ž˜›ȱ ’‘ȱ›Ž•ŠŽȱœŽ›Ÿ’Œ’—ȱŠ—ȱŠ“žœ–Ž—œȱ’œȱ
Œ˜ŸŽ›Žȱ‹Ž’——’—ȱ˜—ȱ™ŠŽȱśǯŗŗǯȱ
:$51,1*([SORVLYH)XHO
Šœ˜•’—Žȱ’œȱŽ¡›Ž–Ž•¢ȱ̊––Š‹•ŽȱŠ—ȱ’œȱŸŠ™˜›œȱŒŠ—ȱŽ¡™•˜Žȱ
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Ž••ȱŸŽ—’•ŠŽǰȱž—˜ŒŒž™’Žȱ‹ž’•’—œǰȱŠ Š¢ȱ›˜–ȱœ™Š›”œȱ˜›ȱ
̊–Žœǯȱ˜ȱ—˜ȱꕕȱ‘ŽȱžŽ•ȱŠ—”ȱ ‘’•Žȱ‘ŽȱŽ—’—Žȱ’œȱ‘˜ȱ˜›ȱ
›ž——’—ǰȱœ’—ŒŽȱœ™’••ŽȱžŽ•ȱŒ˜ž•ȱ’—’Žȱ’ȱ’ȱŒ˜–Žœȱ’—ȱŒ˜—ŠŒȱ
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Ž—’—Žȱ—ŽŠ›ȱœ™’••ŽȱžŽ•ǯȱŽŸŽ›ȱžœŽȱŠœ˜•’—ŽȱŠœȱŠȱŒ•ŽŠ—’—ȱ
ŠŽ—ǯ
7URXEOHVKRRWLQJ&DUEXUHWRU5HODWHG&DXVHV
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ȱ ŗǯȱ —’—ŽȱœŠ›œȱ‘Š›ǰȱ›ž—œȱ›˜ž‘•¢ȱ
˜›ȱœŠ••œȱŠȱ’•Žȱœ™ŽŽǯ
3RVVLEOH&DXVH3UREDEOH5HPHG\
ȱ ŗǯȱ ˜ ȱ’•ŽȱžŽ•ȱ–’¡ž›Žȱǻœ˜–Žȱ–˜Ž•œǼȦœ™ŽŽȱ’–™›˜™Ž›•¢ȱŠ“žœŽǯȱ
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ȱ Řǯȱ —’—Žȱ›ž—œȱ›’Œ‘ȱǻ’—’ŒŠŽȱ‹¢ȱ
ȱ؊ǯȱ •˜ŽȱŠ’›ȱŒ•ŽŠ—Ž›ǯȱ•ŽŠ—ȱ˜›ȱ›Ž™•ŠŒŽǯ
‹•ŠŒ”ǰȱœ˜˜¢ȱŽ¡‘Šžœȱœ–˜”Žǰȱ
ȱ ‹ǯȱ ȱ‘˜”Žȱ™Š›’Š••¢ȱŒ•˜œŽȱž›’—ȱ˜™Ž›Š’˜—ǯȱ‘ŽŒ”ȱ‘ŽȱŒ‘˜”Žȱ•ŽŸŽ›Ȧ
–’œę›’—ǰȱ•˜œœȱ˜ȱœ™ŽŽȱŠ—ȱ™˜ Ž›ǰȱ
•’—”ŠŽȱ˜ȱŽ—œž›ŽȱŒ‘˜”Žȱ’œȱ˜™Ž›Š’—ȱ™›˜™Ž›•¢ǯ
˜ŸŽ›—˜›ȱ‘ž—’—ǰȱ˜›ȱŽ¡ŒŽœœ’ŸŽȱ
ȱ Œǯȱ ˜ ȱ’•ŽȱžŽ•ȱ–’¡ž›Žȱ’œȱ’–™›˜™Ž›•¢ȱŠ“žœŽǯȱ“žœȱ•˜ ȱ’•Žȱ
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žŽ•ȱ—ŽŽ•Žȱǻœ˜–Žȱ–˜Ž•œǼǯ
ȱ ǯȱ •˜Šȱ•ŽŸŽ•ȱ’œȱœŽȱ˜˜ȱ‘’‘ǯȱŽ™Š›ŠŽȱŒŠ›‹ž›Ž˜›ȱŠ’›ȱ‘˜›—ȱ›˜–ȱ
ŒŠ›‹ž›Ž˜›ȱ‹˜¢ǰȱŠ“žœȱ̘Šȱ˜ȱœ™ŽŒ’ęŒŠ’˜—ǯ
ȱ Žǯȱ ’›ȱž—Ž›ȱ‘ŽȱžŽ•ȱ’—•Žȱ—ŽŽ•ŽǯȱŽ–˜ŸŽȱ—ŽŽ•ŽDzȱŒ•ŽŠ—ȱ—ŽŽ•ŽȱŠ—ȱ
œŽŠȱŠ—ȱ‹•˜ ȱ ’‘ȱŒ˜–™›ŽœœŽȱŠ’›ǯ
ȱ ǯȱ ˜ •ȱŸŽ—ȱ˜›ȱŠ’›ȱ‹•ŽŽœȱ™•žŽǯȱŽ–˜ŸŽȱ•˜ ȱ’•ŽȱžŽ•ȱŠ“žœ’—ȱ
—ŽŽ•Žǯȱ•ŽŠ—ȱŸŽ—ǰȱ™˜›œǰȱŠ—ȱŠ’›ȱ‹•ŽŽœǯȱ•˜ ȱ˜žȱŠ••ȱ™ŠœœŠŽœȱ
’‘ȱŒ˜–™›ŽœœŽȱŠ’›ǯ
ȱ ǯȱ ŽŠ”¢ǰȱŒ›ŠŒ”Žȱ˜›ȱŠ–ŠŽȱ̘Šǯȱž‹–Ž›Žȱ̘Šȱ˜ȱŒ‘ŽŒ”ȱ˜›ȱ
•ŽŠ”œǯ
ȱ řǯȱ —’—Žȱ›ž—œȱ•ŽŠ—ȱǻ’—’ŒŠŽȱ‹¢ȱ
ȱřŠǯȱ ˜ ȱ’•ŽȱžŽ•ȱ–’¡ž›Žȱ’œȱ’–™›˜™Ž›•¢ȱŠ“žœŽǯȱ“žœȱ•˜ ȱ’•Žȱ
–’œę›’—ǰȱ•˜œœȱ˜ȱœ™ŽŽȱŠ—ȱ™˜ Ž›ǰȱ
žŽ•ȱ—ŽŽ•Žȱǻœ˜–Žȱ–˜Ž•œǼǯ
˜ŸŽ›—˜›ȱ‘ž—’—ȱ˜›ȱŽ¡ŒŽœœ’ŸŽȱ
ȱ ‹ǯȱ ȱ•˜Šȱ•ŽŸŽ•ȱ’œȱœŽȱ˜˜ȱ•˜ ǯȱŽ™Š›ŠŽȱŒŠ›‹ž›Ž˜›ȱŠ’›ȱ‘˜›—ȱ›˜–ȱ
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Section 5A
LPG Fuel Systems
Section 5A
LPG Fuel Systems
WARNING: Explosive Fuel!
LPG is extremely flammable, is heavier than air, and tends to settle in low areas where a spark or flame could ignite the gas.
Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger the safety of
persons in the area.
Proper service and repair of LPG fuel systems requires qualified technicians and special equipment. Many states
require special licensing or certification for LPG repair shops and/or technicians. Check state and local
regulations before attempting any adjustment, service, or repair of the LPG system or components. Faulty
repairs by unqualified or underqualified personnel can have very serious ramifications. The information in this
segment is for the exclusive use of qualified LPG service providers.
LPG Fuel System Components
The typical “liquid withdrawal” LPG fuel system consists of the following components:
• LPG Fuel Tank (Liquid Withdrawal)
• Electric Lock-Off/Filter Assembly
• Vaporizer
• LPG Regulator (Combination Primary/Secondary/Vacuum Lock-Off)
• LPG Carburetor
• High Pressure Fuel Line(s)
• Vacuum Line
Fuel Line
Vaporizer
Vacuum Line
Lock-Off/Filter
Assembly
LPG Regulator
Figure 5A-1.
5A.1
5A
Section 5A
LPG Fuel Systems
Operation
In a liquid withdrawal system, the Liquefied
Petroleum Gas (LPG) is released from the bottom of
the supply tank under high pressure. Upon opening
the shut-off valve on the tank, liquid fuel travels out
through the high pressure line to the electric lock-off/
filter assembly. The lock-off opens internally when the
key switch is turned “on,” permitting filtered fuel to
flow to the vaporizer. The vaporizer is mounted in the
flow of the discharged cooling air. It absorbs heat from
the cooling air and transfers it to the fuel, changing the
liquefied petroleum to a vapor or gaseous state, while
partially stepping down the fuel pressure. The gas/
vapor flows under this decreased pressure to the
regulator where it is further reduced to a usable,
regulated pressure. The regulator, activated by intake
manifold vacuum, controls fuel flow to the carburetor.
In the venturi of the carburetor, the fuel vapor is
mixed with incoming air from the air cleaner in the
correct ratio for efficient combustion.
Troubleshooting Checklist
If the engine starts hard, runs roughly, or stalls, check
the following areas.
•
Make sure the LPG fuel tank is filled and shut-off
valve is fully opened.
•
Make sure fuel is reaching the carburetor.
•
Make sure the air cleaner element and precleaner
are clean and all components are fastened
securely.
•
Make sure the ignition, governor, exhaust,
throttle, and choke control systems are all
operating properly.
•
Check compression.
If engine continues to start hard, run roughly, or stall
after these checks have been made, use the following
troubleshooting guide.
Engine cranks but will not start
1. LPG fuel tank closed, low, or empty.
2. Lock-off not opening electrically, preventing fuel
flow to vaporizer.
3. Fuel filter (located inside lock-off) dirty or
blocked.
5A.2
4. Insufficient vacuum signal, regulator not opening.
a. Vacuum line between carburetor and
regulator cracked, leaking, kinked, or pinched.
b. Carburetor loose.
c. Intake manifold loose or leaking.
d. Excessive internal engine wear.
5. Faulty regulator.
a. Primary valve not opening.
b. Diaphragm spring adjustment incorrect.
c. Idle adjustment screw incorrectly set.
d. Vent(s) blocked/restricted.
6. Restricted/blocked fuel line.
7. Blocked carburetor fuel circuit.
8. Loose/leaking fuel enrichment hose (Impco
carburetor system).
Hard starting, runs roughly, or stalls at idle speed
1. LPG fuel tank low.
2. Vacuum line between carburetor and regulator
pinched, cracked, or leaking.
3. Carburetor idle speed set too low (should be at
least 1200 RPM).
4. Carburetor idle circuit restricted.
5. Dirty/restricted air cleaner.
6. Dirty/restricted lock-off filter.
7. Frozen/malfunctioning regulator. Check/adjust
primary pressure.
8. Excessive external load on engine.
9. Excessive internal wear.
10. Loose/leaking fuel enrichment hose (Impco
carburetor system).
Irregular or inconsistent idle
1. Improper operation/adjustment of regulator, idle
adjustment screw, throttle opening, and/or engine
governor.
2. Secondary valve in regulator not closing. Readjust
idle screw (couterclockwise) so valve can close
fully against seat.
3. Loose/leaking vacuum line.
4. Loose carburetor mounting and/or line
connections.
5. Damaged diaphragm(s) within regulator.
6. Debris in regulator. Flush debris from drain plug
or remove regulator from system, disassemble
body and remove debris.
7. Dirt or debris in carburetor. Remove carburetor,
disassemble and clean/service as required. If
venturi (Impco carburetor) removal is performed,
mark its orientation to the carburetor body for
proper reinstallation.
8. Loose/leaking fuel enrichment hose (Impco
carburetor system).
Section 5A
LPG Fuel Systems
Engine stalls during operation
1. No fuel.
2. Faulty lock-off or blocked filter.
3. Improper governor setting.
4. Damaged diaphragms within regulator.
5. Vacuum line leaking, loose, or pinched.
6. Restricted fuel line.
7. Loose/leaking fuel enrichment hose (Impco
carburetor system).
Low power
1. Air cleaner or exhaust system dirty/restricted.
2. Low fuel.
3. Rich gas condition (flooding) through regulator.
a. Dirty/restricted valves in regulator.
b. Damaged primary diaphragm in regulator.
4. No fuel.
a. Electric lock-off not opening, filter blocked, or
restriction within fuel line.
b. Leaking, loose, or cracked vacuum line from
carburetor to regulator.
c. Leaking, or loose intake system components.
d. Regulator primary valve not opening.
e. Secondary, or vacuum lock-off diaphragm
within regulator leaking.
f. Low pressure rubber hose kinked.
g. Frozen regulator.
5. Improper ignition timing.
6. Loose/incorrect throttle lever/clamp bracket
positioning.
7. Loose or incorrectly positioned high speed
throttle plate stop.
LPG Carburetor Adjustments
General
The LPG carburetor and regulator are designed to
deliver the correct fuel-to-air mixture to the engine
under all operating conditions. The high and low idle
fuel mixture settings are preset at the factory, and
cannot be adjusted. These engines are equipped with
an Impco or Nikki carburetor. See Figure 5A-2 and
5A-3. Although both carburetors function similarly,
each is unique and should not be interchanged.
Load Block Assembly
Fuel Enrichment
Hose
Venturi
Retaining
Screw
Idle Speed
Adjusting Screw
Fuel Inlet
Figure 5A-2. Impco Carburetor.
Choke Plate/Shaft Assembly
Rear Plug
with Sealing
Washer
Transfer
Chamber
Cover
Engine runs lean
1. Electrical problem causing intermittent lock-off
operation, or lock-off is faulty.
2. Filter in lock-off dirty or restricted.
3. Restriction in fuel system.
4. Idle holes plugged; dirt in fuel delivery channels.
5. Carburetor fuel circuit restriction.
6. Loose/leaking fuel enrichment hose (Impco
carburetor system).
Figure 5A-3. Nikki Carburetor.
High fuel consumption
1. Fuel leak. Check lines, connections, and system
components for leaks with soapy water. Fix any
leaks immediately.
2. Incorrectly set regulator, or leakage from valves
in regulator. Readjust, service, or replace
regulator as required.
3. Dirty air cleaner or precleaner.
4. Choke plate in carburetor not opening
completely.
Impco carburetors also incorporate the use of an
external ‘‘Load Block’’ assembly, which controls the
final fuel flow to the carburetor for all throttle
positions except idle. See Figure 5A-2. Calibrated and
flow-matched to the carburetor, it functions similarly
to preset fuel mixture settings in other carburetors.
The load block assembly is not available separately,
nor is any internal servicing permitted or possible. If a
problem is encountered and determined to be caused
by the load block, the carburetor should be replaced.
Fuel Inlet
Plastic Bushing
Vacuum Port
Idle Speed
Adjusting Screw
5A.3
5A
Section 5A
LPG Fuel Systems
High Altitude Operation
The standard carburetor calibrations will provide
proper operation up to altitudes of 1500 m (5000 ft.).
No internal changes are necessary or available for
either carburetor.
NOTE: Carburetor adjustments should be made only
after the engine has warmed up.
Idle Speed Adjustment
1. Start the engine and run at half throttle for 5 to 10
minutes. Check that the throttle and choke (Nikki
carburetor) plates can open fully.
Impco Carburetor
1. Turn off fuel supply at tank.
2. Remove the air cleaner, breather hose, fuel line,
vacuum hose, choke, and throttle linkages.
Remove the mounting hardware, carburetor, and
gaskets from the engine. Discard the gaskets.
3. The carburetor venturi may be removed for
inspection and appropriate cleaning.
a. Remove the four screws securing the air
cleaner adapter and gasket to the carburetor.
See Figure 5A-4.
2. Place the throttle control into the “idle” or
“slow” position. Turn the low idle speed
adjusting screw (See Figure 5A-2 or 5A-3) in or
out, to obtain a low idle speed of 1200 RPM (± 75
RPM), or set to application specifications. Check
the speed using a tachometer.
NOTE: The actual low idle speed (RPM) depends on
the application. Refer to the equipment
manufacturer’s recommendations. The low
idle speed for basic engines is 1200 RPM.
LPG Fuel System Component Service
LPG Carburetor - Cleaning
The carburetor may be cleaned if necessary. Removal
from the engine and limited disassembly will aid in
cleaning.
NOTE: Impco Carburetor: Do not loosen or alter the
mounted position of the clamping brackets
and/or stop collar on the throttle shaft. Each
is preset, in correlation to a specific position
of the throttle plate (shaft), or acts as a stop.
None of these attached components,
including the throttle plate or shaft, requires
disassembly or removal for any carburetor
servicing. All the components on the throttle
shaft should be left intact. If the settings of
any one of these is inadvertently loosened or
altered, each must be checked/reset, or
performance and operation will be affected.
Refer to the procedure included in the
reassembly/installation sequence to check or
reset.
Figure 5A-4.
b. Important: Mark a small line on the outer
edge of the venturi for proper orientation and
reinstallation later.
c. Loosen the venturi retaining screw on the side
of the carburetor body and lift out the
venturi. See Figure 5A-5.
Figure 5A-5.
5A.4
Section 5A
LPG Fuel Systems
4. Inspect the overall condition of the fuel
enrichment hose attached to the carburetor. It
must be free of cracks, deterioration, and damage.
Disconnect the fuel enrichment hose from the
carburetor fittings to clean or check condition as
required. See Figure 5A-6. Replace with a new
Kohler high pressure hose (LP rated) if the
condition is questionable in any way. Secure new
hose using new clamps.
Nikki Carburetor
1. Turn off fuel supply at tank.
2. Remove the air cleaner, breather hose, fuel line,
vacuum hose, choke, and throttle linkages.
Remove the nuts, carburetor, and gaskets from
the engine. Discard the gaskets.
3. Remove the fuel transfer chamber cover by
removing the three screws. See Figure 5A-3.
Carefully remove the cover and gasket. Discard
the gasket.
4. The main jet is fixed and nonadjustable, but may
be accessed for cleaning by removing the rear
plug and sealing washer. Discard the washer.
Figure 5A-6.
5. Clean all parts as required, use a good carburetor
cleaner, following the manufacturer's
instructions. Blow clean, compressed air through
all the passages. Do not poke or probe into the
load block assembly as damage can be done,
resulting in serious operational problems. See
Figure 5A-7.
5. In order to clean the off-idle transfer passages
and carburetor thoroughly, use a good carburetor
cleaner and follow the manufacturer's
instructions. Blow clean, compressed air through
the passages and make sure all are open before
reassembling. Do not use wire or metal objects to
clean passages or carburetor body.
LPG Carburetor - Inspection
1. Inspect the carburetor body and removable
venturi (Impco carburetor) for cracks, holes, and
other wear or damage.
2. Check the choke shaft (Nikki carburetor only)
and the throttle shaft for wear and free
movement.
NOTE: Do not attempt to disassemble or
remove either shaft from the carburetor
body, including the mounted clamp
brackets on Impco style carburetors. The
screws, attaching the choke and throttle
plate to their respective shafts are staked
or bonded to prevent loosening. The
plate(s) and shaft(s) are not available
separately. If detrimental wear or
damage is found in any of the parts, the
carburetor should be replaced.
Figure 5A-7.
5A.5
5A
Section 5A
LPG Fuel Systems
LPG Carburetor - Reassembly
Impco Carburetor
1. Slide the venturi into the carburetor body,
aligning the position mark made prior to
removal. Correctly installed, the discharge holes
should not be visible from the top.
Idle Speed Clamp Bracket Position
1. Counting the number of turns, back the idle
speed adjustment screw off (counterclockwise),
so only 1 to 1 1/2 of the threads are visible. See
Figure 5A-8.
2. Secure with the venturi retaining screw. Torque
the screw to 4.0 N·m (36 in. lb.).
3. Install a new adapter gasket and mount the air
cleaner adapter onto the carburetor with the four
screws. Torque the screws to 4.0 N·m (36 in. lb.).
Idle Speed
Clamp
Bracket
Mounting
Screw
4. Install a new carburetor gasket onto the intake
manifold adapter, followed by the carburetor.
Install and finger tighten the mounting fasteners.
5. Connect the ‘‘Z’’ end of the throttle linkage and
the dampening spring to the throttle clamp
bracket on the throttle shaft. Attach the opposite
end of linkage and spring to the governor lever.
NOTE: The clamp brackets and stop collar
mounted on the throttle shaft should still
be in their original positions (See Figure
5A-2), and not require any readjustment/
resetting. Continue with steps 6 and 7. If
the mounted position of any one of these
was affected or changed, it will be
necessary to check and reset the position
of each before proceeding. Follow the
complete instructions listed after step 7,
then continue with steps 6 and 7.
Figure 5A-8. Backing Off Idle Speed Screw.
2. Loosen the clamp bracket mounting screw, and
pivot the throttle shaft to fully close the throttle
plate. See Figure 5A-9.
6. Manually move the governor lever toward the
carburetor as far as it will go.
7. Check that the throttle plate is now fully open or
reposition the carburetor slightly on the
mounting screws so it is fully open. Torque the
mounting screws to 9.9 N·m (88 in. lb.).
Instructions for Checking/Positioning the Clamp
Brackets Mounted on the Throttle Shaft
Use only if the position or mounting of the clamp
bracket(s) has been disturbed. Figures show the
carburetor removed from the engine for clarity.
5A.6
Figure 5A-9. Closing Throttle Plate.
3. Hold the throttle plate closed and rotate the
clamp bracket until the end of the screw contacts
the stop. Insert a 0.025 mm (0.001 in.) feeler gauge
between the carburetor housing and the side of
the clamp bracket to set the endplay, then tighten
the mounting screw securely. See Figure 5A-10.
Section 5A
LPG Fuel Systems
3. Insert a 0.025 mm (0.001 in.) feeler gauge between
the side of the stop collar and the carburetor
housing, then check or set the position of the stop
collar. The head of the mounting screw must be
in contact with the carburetor boss from the back
(hose/fitting) side, preventing any further
rotation over center. Set or adjust the stop collar
as required. See Figure 5A-12.
Figure 5A-10. Tightening Idle Speed Clamp
Mounting Screw.
High Speed Stop
Collar
4. Reset the idle speed adjustment screw back to the
original position.
High Speed/Stop Collar Position
1. Make sure the idle speed clamp position has
already been checked or properly set.
2. Rotate and hold the throttle shaft so the throttle
plate is fully open/perfectly vertical. See Figure
5A-11.
5A
Figure 5A-12. Adjusting/Setting Stop Collar.
4. Tighten the screw securely.
NOTE: After the idle speed clamp bracket and the
high speed stop collar positions have been
set, check that the throttle shaft pivots freely
without binding or restriction.
Throttle Linkage Clamp Bracket Position
Carburetor must be assembled to engine with linkage
attached to set this position.
High Speed Stop
Collar
1. The throttle linkage clamp bracket should be
positioned as shown in Figure 5A-13 on the idle
speed clamp bracket side of the throttle shaft.
Figure 5A-11. Full Throttle Position.
Throttle
Linkage
Clamp Bracket
Figure 5A-13. Throttle Linkage Clamp Bracket
Position.
5A.7
Section 5A
LPG Fuel Systems
2. Manually move the governor lever, with the
throttle linkage connected, toward the carburetor as
far as it will go. Hold it in this position.
3. Looking down the throat of the carburetor, check
that the throttle plate is in the full throttle position
and that the head of the high speed collar stop
screw is in contact with the carburetor boss. If not,
loosen the carburetor mounting screws and
reposition the carburetor slightly. Torque the
carburetor mounting screws to 9.9 N·m (88 in. lb.).
NOTE: If additional adjustment is required,
loosen the throttle linkage clamp bracket
mounting screw, set the throttle shaft to
the full throttle position against the head
of the stop screw, and retighten the clamp
mounting screw securely. See Figure
5A-14.
6. Check to be sure all system connections are tight.
7. Reset idle RPM and recheck high idle (governed
speed) after starting and allowing sufficient
warm-up time.
Electric Lock-Off/Filter Assembly - Functional Test
The electric lock-off can be easily tested to verify that
it is functional. Remove it from the system for testing.
Using a 12 volt power supply or battery, connect one
wire lead to the positive (+) lead of power supply, and
touch remaining wire lead to negative (-) lead of
power supply. When connection is made, an audible
“click” should be heard indicating the opening of the
lock-off. While energized, blow compressed air
through it to determine if it is blocked or restricted.
Figure 5A-15.
Figure 5A-14. Tightening Throttle Linkage Clamp
Bracket.
Nikki Carburetor
1. Reinstall the rear plug with a new sealing washer.
Tighten the plug securely.
2. Reinstall fuel transfer chamber cover with a new
gasket. Secure with the three screws.
3. Install new carburetor mounting gasket on
manifold studs, followed by the carburetor and
new air cleaner base gasket.
Figure 5A-16.
4. Reconnect the throttle and choke linkages, and
the fuel and vacuum lines.
5. Reinstall the air cleaner base and breather tube.
Secure base with two mounting nuts. Torque nuts
to 9.9 N·m (88 in. lb.). Install the rest of the air
cleaner system.
5A.8
Electric Lock-Off/Filter Assembly - Filter Service
The filter inside the lock-off assembly should be
replaced every 500 hours of operation, or if it becomes
blocked or restricted. Cleaning of the filter element is
not recommended. Order a replacement filter element
by the appropriate Kohler part number.
Section 5A
LPG Fuel Systems
Vaporizer Assembly
The outer surface of the vaporizer should be kept free
of dirt and debris accumulation, which will cause a
loss of vaporization efficiency. Visual inspection and
necessary cleaning should be performed on a regular
basis, more frequently under dusty or dirty
conditions. The vaporizer should be disassembled,
cleaned, and serviced using a rebuild kit every 1500
hours or if a problem is encountered.
Figure 5A-18. Impco (Beam) Regulator.
5A
Figure 5A-17.
LPG Regulator
The regulator controls both the pressure and flow of
fuel within the LP system. It is comprised of both a
primary and secondary chamber, which are dependent
upon one another. Two different styles of regulators
are used, based upon the system involved. The Impco
(Beam) regulator is shown in Figure 5A-18, and the
Nikki regulator is shown in Figure 5A-19. Although
the basic design and operating principles are similar,
due to system differences the regulators should not be
interchanged.
Figure 5A-19. Nikki Regulator.
Following are separate sections covering the theory of
operation and general service information for each
style of regulator. Detailed service/repair instructions
are included in the rebuild kit for each regulator.
5A.9
Section 5A
LPG Fuel Systems
Impco (Beam) Regulator (See Figure 5A-20)
LPG vapor enters at point (A), then passes into
primary area (B) at point (28), where pressure is
reduced from up to 250 psi at the tank to 4.5 psi in
area (B). Fuel pressure against diaphragm (2)
overcomes spring (3) and as movement increases,
spring (5) will close lever (6). The primary diaphragm
breather (not shown in drawing) is vented to
secondary chamber so that rupture of this diaphragm
would direct fuel into the carburetor.
19
1
17
14
20
15
5
E
2
25
18
16
3
B
13
H
4
12
K
Fuel now moves through passage (E), past secondary
valve (25) into secondary area (C). As negative
pressure (vacuum) is created at the carburetor venturi
and is transmitted through the dry-gas hose to
chamber (C) secondary diaphragm (12) is drawn
down and contacts the secondary lever (16). Fuel will
flow in proportion to air velocity through the
carburetor venturi, ensuring an ideal mixture at all
engine speeds.
Whenever the engine is operating, the vacuum
diaphragm (10) is down against the floor (H) and the
spring (11) is compressed. The idle and starting
adjustment is made with a tamper-resistant screw (17)
which regulates the whisker wire system (not shown),
opening up the secondary orifice slightly (but only
when the vacuum diaphragm is drawn down). Very
little vacuum is needed to start this vacuum
diaphragm travel: 0.2 in. Mercury to start and 0.5 in.
Mercury for full travel. The instant the engine stops
rotating, loss of vacuum in section (D) releases
diaphragm (10) causing bumper (K) to push against
secondary lever (16), overcoming action of whisker
wire and ensuring 100% lock-off.
This patented Beam design will lock off primary
pressures up to five times in excess of normal and
permits starting without priming or choking.
5A.10
D
6
7
C
28
11
A
8
10
9 21
1. 1/8-27 NPT Plug
2. Primary Diaphragm Assembly
3. Primary Spring
4. Expansion Plug
5. Secondary Diaphragm Spring
6. Primary Lever Assembly
7. Fillister Head Screw
8. Primary Pivot Pin
9. Torx Head Screw
10. Vac Lock Diaphragm
Assembly
11. Vac Lock Spring
Figure 5A-20.
12. Secondary Diaphragm
13. Pan Head Screw
14. Secondary Lever Spring
15. Secondary Pivot Pin
16. Secondary Lever
Assembly
17. Adjustment Screw
18. Pan Head Screw
19. Expansion Plug
20. Diaphragm Gasket
21. Split Lock Washer
Section 5A
LPG Fuel Systems
Nikki Regulator Primary Chamber
(See Figure 5A-21)
The primary chamber reduces the high pressure fuel
flow from the tank and vaporizer down to
approximately 4 psi. Fuel flowing from the vaporizer
enters the inlet of the regulator under approximately
76 kPa (11 psi) of pressure. There it is delivered to the
primary chamber (3) through the clearance between
the primary valve (1) and valve seat (2). As fuel
continues to flow and the primary chamber
approaches 29 kPa (4 psi), the primary diaphragm (4)
overcomes the tension of the diaphragm spring (5). As
the diaphragm (4) and contact button (6) move up, the
primary lever spring (8) pushes the primary lever (7)
up, in turn closing the primary valve (1) and stopping
the flow of fuel. As fuel is consumed and the pressure
in the primary chamber drops below 29 kPa (4 psi), the
diaphragm spring (5) tension will be greater than the
fuel pressure, causing the primary diaphragm (4) to be
pushed down. This causes the contact button (6), to
push the primary lever (7) down, in turn opening the
primary valve (1) and admitting more fuel. In this
manner, the pressure within the primary chamber is
maintained at a relatively constant 29 kPa (4 psi).
9
7
4
5
1
6
3
2
8
Fuel
Inlet
To Secondary Chamber
1. Primary Valve
6. Contact Button
2. Primary Valve Seat
7. Primary Valve Lever
3. Primary Chamber
8. Primary Lever Spring
4. Primary Diaphragm
9. Primary Pressure
5. Primary Diaphragm Spring Adjustment
Figure 5A-21. Primary Chamber.
Nikki Regulator Secondary Chamber
(See Figure 5A-22)
The secondary chamber further reduces the fuel
pressure from the 29 kPa (4 psi) of the primary
chamber to near 0 kPa (0 psi) pressure, to prevent
excessive fuel flow to the carburetor. Fuel enters the
secondary chamber (13) through the clearance
between the secondary valve (11) and the valve seat
(12). While the engine is operating, and fuel is being
drawn from the secondary chamber, the secondary
diaphragm (14) is raised by atmospheric pressure,
simultaneously lifting the secondary valve lever (16),
opening the secondary valve (11), allowing fuel to
flow. When the engine is running at idle, there may
not be enough vacuum created in the carburetor
venturi to overcome the tension of the secondary
diaphragm spring (15), and the secondary diaphragm
cannot open the valve. Under those conditions, the
idle adjusting screw (18), and balance spring (19) are
used to apply just enough pressure on the diaphragm
(14) to maintain sufficient fuel flow for idle operation.
The vacuum lock-off mechanism is located in the
secondary chamber. When the engine is running,
manifold vacuum above the diaphragm (17) draws it
up, so the secondary valve can function normally.
When the engine is stopped, manifold vacuum is
terminated, and the diaphragm relaxes and pushes
down on the secondary valve lever, preventing any
fuel flow or leakage through the regulator.
From Primary
Chamber
12
17
To Intake
Manifold
11
13
To
15 16
18
Carburetor
11. Secondary Valve
12. Secondary Valve Seat
13. Secondary Chamber
14. Secondary Diaphragm
15. Secondary Diaphragm Spring
19
14
16. Secondary Valve Lever
17. Vacuum Lock-Off
Diaphragm
18. Idle Adjust Screw
19. Balance Spring
Figure 5A-22. Secondary Chamber.
5A.11
5A
Section 5A
LPG Fuel Systems
Preventative Maintenance
The regulator is preset at the factory and generally
requires no further adjustment. No periodic service is
required. Over time, depending on fuel quality,
operating environment, and system performance, fuel
deposits can accumulate inside the regulator. Those
regulators containing a drain plug (Nikki) should be
drained every 500 hours to remove any accumulated
deposits. See Figure 5A-23.
Regulator Service
Every 1500 hours it is recommended that
disassembly, cleaning, and resetting of the regulator
be performed using the regulator rebuilding kit
available. Specific instructions are included in the
rebuilding kit. Perform the regulator service
following the instructions provided. As all
adjustments and settings must be reset using specific
test equipment, this must be performed by qualified
LP personnel only.
Impco (Beam) Regulator Service
Kohler repair kit 24 757 40-S should be used to service
the regulator every 1500 hours, or whenever cleaning
and servicing is required.
Nikki Regulator Service
Kohler repair kit 24 757 39-S should be used every
1500 hours.
Regulator Drain Plug
Figure 5A-23. Regulator Drain Plug (Some Models).
1. Turn supply valve off, run engine out of fuel, and
turn off ignition switch.
2. Disconnect and ground the spark plug leads.
3. Remove the 1/8" pipe plug from bottom of
regulator and drain any accumulated deposits.
See Figure 5A-23.
4. Reinstall plug using pipe sealant with Teflon®
(Loctite® 592 or equivalent) on threads and
tighten securely. If required, a replacement plug
is available as Kohler Part No. X-75-23-S.
5A.12
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Section 7
Retractable Starter
WARNING: Spring Under Tension!
Retractable starters contain a powerful, recoil spring that is under tension. Always wear safety goggles when servicing
retractable starters and carefully follow instructions in this section for relieving spring tension.
To Remove Starter
1. Remove the five hex flange screws securing the
starter to the blower housing.
Hex
Flange
Screws
2. Remove the starter.
Starter Housing
Handle with
Rope Retainer
To Install Starter
1. Install the retractable starter onto the blower
housing, leaving the five hex flange screws
slightly loose.
2. Pull the starter handle out until the pawls
engage in the drive cup. Hold the handle in this
position and tighten the screws securely.
Rope Replacement
The rope can be replaced without complete starter
disassembly.
Spring and
Keeper
7
Pulley
Pawl Springs
Brake Washer
Brake Spring
1. Remove the starter from the blower housing.
2. Pull the rope out approximately 12 in. and tie a
temporary (slip) knot in it to keep it from
retracting into the starter. See Figure 7-2.
Rope
Pawls
Pawl Retainer
Plain Washer
Center Screw
Drive Cup
Figure 7-1. Retractable Starter - Exploded View.
7.1
Section 7
Retractable Starter
Slipknot
Handle
Keep Pulley
from Rotating
Rope
Guide
Bushing
Rope Hole
in Pulley
Knot
Rope Retainer
Figure 7-2. Removing Starter Handle.
3. Remove the rope retainer from inside the starter
handle. Untie the single knot and remove the
rope retainer and handle.
4. Hold the pulley firmly and untie the slipknot.
Allow the pulley to rotate slowly as the spring
tension is released.
5. When all spring tension on the starter pulley is
released, remove the rope from the pulley.
6. Tie a single knot in one end of the new rope.
7. Rotate the pulley counterclockwise (when
viewed from pawl side of pulley) until the spring
is tight (approximately 6 full turns of pulley).
8. Rotate the pulley clockwise until the rope hole in
the pulley is aligned with the rope guide bushing
of the starter housing.
NOTE: Do not allow the pulley/spring to
unwind. Enlist the aid of a helper if
necessary, or use a C-clamp to hold the
pulley in position.
9. Insert the new rope through the rope hole in the
starter pulley and the rope guide bushing of the
housing. See Figure 7-3.
7.2
Figure 7-3. Installing Rope.
10. Tie a slipknot approximately 12 in. from the free
end of rope. Hold the pulley firmly and allow it
to rotate slowly until the slipknot reaches the
guide bushing of the housing.
11. Slip the handle and rope retainer onto the rope.
Tie a single knot at the end of the rope. Install the
rope retainer into the starter handle.
12. Untie the slipknot and pull on the handle until
the rope is fully extended. Slowly retract the rope
into the starter. When the spring is properly
tensioned, the rope will retract fully and the
handle will stop against the starter housing.
Pawls (Dogs) Replacement
To replace the pawls, follow disassembly steps 1-4
and reassembly steps 3-8 on the following pages. A
pawl repair kit is available which includes the
following components:
Qty.
1
1
2
1
2
1
1
Description
Pawl Retainer
Center Screw
Pawl (Dog) Spring
Brake Spring
Starter Pawl (Dog)
Brake Washer
Washer
Section 7
Retractable Starter
Disassembly
WARNING: Spring Under Tension!
Do not remove the center screw from the starter until the spring
tension is released. Removing the center screw before releasing
spring tension, or improper starter disassembly, can cause the
sudden and potentially dangerous release of the spring. Follow
these instructions carefully to ensure personal safety and
proper starter disassembly. Make sure adequate face protection
is worn by all persons in the area.
1. Release the spring tension and remove the
handle and the starter rope. (Refer to “Rope
Replacement,” steps 2 through 5 on pages 7.1 and
7.2.)
2. Remove the center screw, washer, and pawl
retainer. See Figure 7-4.
3. Remove the brake spring and the brake washer.
See Figure 7-5.
4. Carefully note the positions of the pawls and
pawl springs before removing them.
Remove the pawls and pawl springs from the
starter pulley.
Center Screw
and Washer
Pawl Retainer
Brake Spring and
Brake Washer
Pawl Spring
Pawls
Figure 7-5. Brake Spring and Washer, Pawls, and
Pawl Springs.
5. Rotate the pulley clockwise 2 full turns. This will
ensure the spring is disengaged from the starter
housing.
6. Hold the pulley in the starter housing. Invert the
pulley/housing so the pulley is away from your
face, and away from others in the area.
7. Rotate the pulley slightly from side to side and
carefully separate the pulley from the housing.
See Figure 7-6.
If the pulley and the housing do not separate
easily, the spring could be engaged in the starter
housing, or there is still tension on the spring.
Return the pulley to the housing and repeat step
5 before separating the pulley and housing.
Housing
Pulley
Figure 7-4. Center Screw, Washer and Pawl
Retainer.
Figure 7-6. Removing Pulley from Housing.
7.3
7
Section 7
Retractable Starter
8. Note the position of the spring and keeper
assembly in the pulley. See Figure 7-7.
Remove the spring and keeper assembly from the
pulley as a package.
WARNING: Spring Under Tension!
Do not remove the spring from the keeper. Severe personal
injury could result from the sudden uncoiling of the spring.
Outer Spring Hook
Reassembly
1. Make sure the spring is well lubricated with
grease. Place the spring and keeper assembly
inside the pulley (with spring towards pulley).
See Figure 7-7.
2. Install the pulley assembly into the starter
housing. See Figure 7-8. Make sure the pulley is
fully seated against the starter housing. Do not
wind the pulley and recoil spring at this time.
Rope Hole
in Pulley
Pulley & Spring
Housing
Spring &
Keeper
Figure 7-7. Position of Spring and Keeper in Pulley.
Inspection and Service
1. Carefully inspect the rope, pawls, housing, center
screw, and other components for wear or
damage.
2. Replace all worn or damaged components. Use
only genuine Kohler replacement parts as
specified in the Parts Manual. All components
shown in Figure 7-1 are available as service
parts. Do not use nonstandard parts.
Figure 7-8. Installing Pulley and Spring into
Housing.
3. Install the pawl springs and pawls into the
starter pulley. See Figure 7-9.
Pawl
3. Do not attempt to rewind a spring that has come
out of the keeper. Order and install a new spring
and keeper assembly.
4. Clean all old grease and dirt from the starter
components. Generously lubricate the spring and
center shaft with any commercially available
bearing grease.
7.4
Pawl Spring
Figure 7-9. Installing Pawls and Pawl Springs.
Section 7
Retractable Starter
4. Place the brake washer in the recess in starter
pulley; over the center shaft.
5. Lubricate the brake spring sparingly with
grease. Place the spring on the plain washer.
Make sure the threads in the center shaft remain
clean, dry, and free of grease and oil.
7. Tension the spring and install the rope and
handle as instructed in steps 6 through 12 under
“Rope Replacement” on page 7.2.
8. Install the starter to the engine blower housing
as instructed in “To Install Starter” on page 7.1.
6. Apply a small amount of Loctite® No. 271 to the
threads of the center screw. Install the center
screw with the washer and retainer to the
center shaft. Torque the screw to 7.4-8.5 N·m
(65-75 in. lb.).
7
7.5
Section 7
Retractable Starter
7.6
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Section 9
Disassembly
Section 9
Disassembly
WARNING: Accidental Starts!
Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment,
disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery cable from battery.
General
Clean all parts thoroughly as the engine is
disassembled. Only clean parts can be accurately
inspected and gauged for wear or damage. There are
many commercially available cleaners that will
quickly remove grease, oil, and grime from engine
parts. When such a cleaner is used, follow the
manufacturer’s instructions and safety precautions
carefully.
Make sure all traces of the cleaner are removed before
the engine is reassembled and placed into operation.
Even small amounts of these cleaners can quickly
break down the lubricating properties of engine oil.
Typical Disassembly Sequence
20.
21.
22.
23.
24.
25.
26.
27.
28.
Remove grass screen and fan.
Remove flywheel.
Remove stator and backing plates.
Remove closure plate assembly.
Remove camshaft.
Remove connecting rods with pistons and rings.
Remove crankshaft.
Remove governor cross shaft.
Remove flywheel end oil seal.
Disconnect Spark Plug Leads
1. Disconnect the leads from the spark plugs. See
Figure 9-1.
NOTE: Pull on boot only, to prevent damage to
spark plug lead.
9
The following sequence is suggested for complete
engine disassembly. The sequence can be varied to
accommodate options or special equipment.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Disconnect spark plug leads.
Shut off fuel supply.
Drain oil from crankcase and remove oil filter.
Remove muffler.
Remove air cleaner assembly.
Remove fuel pump.
Remove control panel (if so equipped).
Remove throttle and choke controls.
Remove external governor controls.
Remove carburetor.
Remove Oil Sentry™ (if so equipped).
Remove electric starter motor.
Remove outer baffles and blower housing.
Remove inner baffles and breather cover.
Remove valve covers.
Remove ignition modules.
Remove intake manifold.
Remove spark plugs.
Remove cylinder heads and hydraulic lifters.
Figure 9-1. Disconnect Both Spark Plug Leads.
Shut Off Fuel Supply
Drain Oil from Crankcase and Remove Oil
Filter
1. Remove the oil fill cap, dipstick, and one of the oil
drain plugs.
9.1
Section 9
Disassembly
3. Remove and discard the oil filter. See Figure 9-5.
Figure 9-2. Removing Dipstick from Tube.
Figure 9-5. Removing Oil Filter.
Figure 9-3. Removing Oil Fill Cap from Cover.
Figure 9-4. Removing Oil Drain Plug.
2. Allow ample time for the oil to drain from the
crankcase and oil filter.
9.2
Figure 9-6. Removing Oil Filter Adapter Nipple.
Section 9
Disassembly
4. Remove the hex flange screws securing the
bracket and base. See Figure 9-8. Two additional
rear screws must be removed if the engine
contains a rear air cleaner support bracket. See
Figure 9-9.
Figure 9-8. Removing Air Cleaner Base Retainer.
Figure 9-7. Removing Oil Cooler.
4. An oil cooler is standard equipment on some
models and an option on others. It may be a cast
aluminum housing, part of the oil filter adapter,
or attached to the blower housing, separated
from the oil filter adapter. If so equipped, remove
the adapter and the cooler. See Figures 9-6 and
9-7.
Remove Muffler
1. Remove the exhaust system and attaching
hardware from the engine. On engines equipped
with a port liner, remove it now.
9
Figure 9-9. Rear Air Cleaner Bracket Screws.
5. Remove the bracket then remove the base and
gasket while carefully pulling the rubber
breather tube through the base. See Figure 9-10.
Remove Air Cleaner Assembly
Standard Air Cleaner
1. Unhook the latches or loosen the knob and
remove the cover. Refer to Section 4.
2. Remove the wing nut from the element cover.
3. Remove the element cover, the air cleaner
element with precleaner and the stud seal.
Figure 9-10. Removing Breather Tube from Base.
9.3
Section 9
Disassembly
Mounting Screws
Figure 9-11. Removing Tube from Breather Cover.
6. Remove the rubber breather tube from the
breather cover. See Figure 9-11.
Figure 9-13. Air Cleaner Bracket Mounting Screws
(Two-Barrel Model Pictured).
4. Remove the heavy-duty air cleaner as an
assembly from the engine. See Figure 9-14.
Heavy Duty Air Cleaner
1. Disconnect the breather hose from the fitting in
adapter or elbow.
2. Remove the two screws (one-barrel carburetor
models), or the four hex flange nuts (two-barrel
carburetor models), securing the adapter or
elbow. See Figure 9-12.
Figure 9-14. Removing Heavy Duty Air Cleaner
Assembly (Two-Barrel Model Pictured).
Breather
Hose
Mounting
Nuts
Figure 9-12. Breather Hose, Mounting Nuts, and
Adapter Elbow (Two-Barrel Model Pictured).
3. Remove the screws securing the main support
bracket for air cleaner to the valve covers. On
two-barrel carburetor models, remove the two
mounting screws into the top of intake manifold.
Unhook the choke return spring if equipped. Do
not lose any of the hardware. See Figure 9-13.
9.4
Remove Fuel Pump
WARNING: Explosive Fuel!
Gasoline is extremely flammable and its vapors can explode if
ignited. Store gasoline only in approved containers, in well
ventilated, unoccupied buildings, away from sparks or flames.
Do not fill the fuel tank while the engine is hot or running,
since spilled fuel could ignite if it comes in contact with hot
parts or sparks from ignition. Do not start the engine near
spilled fuel. Never use gasoline as a cleaning agent.
Pulse Style Pumps
1. Disconnect the fuel lines at the carburetor and at
the in-line fuel filter. See Figure 9-15.
Section 9
Disassembly
3. Remove the two hex flange screws securing the
fuel pump to the bracket or to the blower
housing. See Figure 9-18. The fuel pump body
may be metal or plastic.
Figure 9-15. Disconnecting Fuel Inlet Line at
Carburetor.
Figure 9-18. Removing Screws Holding Fuel Pump
(Metal Bodied Pump Shown).
4. Note or mark the orientation of the fuel pump,
then remove the fuel pump with lines attached
as shown in Figure 9-19.
Figure 9-16. Disconnecting Pulse Line from
Crankcase.
9
Figure 9-19. Remove Fuel Pump and Lines.
Mechanical Fuel Pump
The mechanical style fuel pump is part of the valve
cover assembly. See Figure 9-20.
1. Disconnect the fuel lines at the pump outlet and
at the in-line fuel filter.
Figure 9-17. Disconnecting Pulse Line from Valve
Cover (Early Models).
2. Disconnect the pulse (vacuum) line from the
crankcase, or from the valve cover on earlier
models. See Figures 9-16 and 9-17.
2. The fuel pump will be removed with the valve
cover. Refer to the valve cover removal
procedure.
9.5
Section 9
Disassembly
Figure 9-20. Mechanical Fuel Pump.
Figure 9-22. Rear Air Cleaner Bracket (Some
Models).
Remove Control Panel (If So Equipped)
1. Disconnect the Oil Sentry™ Indicator Light
wires.
2. Mark the spring hole locations and disconnect
the spring from the governor lever. See Figure
9-23.
2. Disconnect the choke control cable from the
control bracket.
3. Disconnect the throttle control cable or shaft.
4. Remove the panel from the blower housing.
Remove Throttle & Choke Controls
1. Remove the four hex flange screws securing the
control bracket and rear air cleaner bracket
(some models) to the cylinder heads. See Figures
9-21 and 9-22.
Figure 9-23. Disconnecting Spring from Bracket.
3. Remove the choke linkage from the choke
actuator lever and carburetor. See Figure 9-24.
Figure 9-21. Removing Control Bracket.
Figure 9-24. Disconnecting Choke Linkage from
Actuator Lever.
9.6
Section 9
Disassembly
Remove External Governor Controls
1. Loosen the hex flange nut and remove the
governor lever from the cross shaft. See Figure
9-25. Leave lever attached to the throttle linkage
and lay assembly on the top of the crankcase.
2. One-Barrel Carburetor Models Only: Remove
the two carburetor mounting screws. See Figure
9-27.
Two-Barrel Carburetor Models Only: If required
use two hex flange nuts locked together and
remove the two carburetor mounting studs on
the starter side of the intake manifold and one of
the studs on the oil filter side.
Pivot the carburetor to clear the breather cover
fitting and pressure switch (if equipped). Remove
the carburetor, throttle linkage, choke linkage,
and the governor lever as an assembly.
Figure 9-25. Removing Governor Lever.
Remove Carburetor
WARNING: Explosive Fuel!
Gasoline is extremely flammable and its vapors can explode if
ignited. Store gasoline only in approved containers, in well
ventilated, unoccupied buildings, away from sparks or flames.
Do not fill the fuel tank while the engine is hot or running,
since spilled fuel could ignite if it comes in contact with hot
parts or sparks from ignition. Do not start the engine near
spilled fuel. Never use gasoline as a cleaning agent.
1. Disconnect the fuel shut-off solenoid lead and
ground lead, if equipped. See Figure 9-26.
Figure 9-27. Removing Carburetor Mounting
Screws.
3. Remove the carburetor, throttle linkage and
governor lever as an assembly. See Figure 9-28.
Ground
Lead
Figure 9-26. Remove Ground Lead (Two-Barrel
Model Pictured).
Figure 9-28. Removing Carburetor Assembly with
Governor Lever Attached.
4. Remove the carburetor gasket.
9.7
9
Section 9
Disassembly
5. If necessary, the carburetor, throttle linkage and
governor lever can be separated. Reattach the
bushings to the linkage following separation to
avoid losing them.
Remove Outer Baffles and Blower
Housing
1. Disconnect the plug from the rectifier-regulator
on the blower housing. See Figure 9-31.
Remove Oil Sentry™ (If So Equipped)
1. Disconnect the lead from the Oil Sentry™ switch.
2. Remove the Oil Sentry™ switch from the
breather cover. See Figure 9-29.
Figure 9-31. Disconnecting Plug from RectifierRegulator.
Figure 9-29. Removing Oil Sentry™ Switch from
Breather Cover.
Remove Electric Starter Motor
2. Use the tip of the dipstick or a similar small flat
tool to bend the locking tang, then remove the B+
(center lead) from the terminal plug as shown in
Figure 9-32. This will allow the blower housing to
be removed without disturbing the wiring
harness.
1. Disconnect the leads from the starter.
2. Remove the two hex flange screws. See Figure
9-30.
Figure 9-32. Remove B+ Lead from Terminal Plug.
Figure 9-30. Removing Electric Starter Motor.
3. Remove the starter assembly and any spacers (if
used).
9.8
3. The rectifier-regulator does not have to be
detached from the blower housing. If the engine
is equipped with SMART-SPARK™ the SAM
module should be removed from the cylinder
baffle or blower housing. See Figure 9-33. The
module willing hang loose as part of the wiring
harness.
Section 9
Disassembly
Figure 9-35. Removing Outer Baffles.
5. Remove the outer baffles on both sides. See
Figure 9-35.
6. On engines equipped with a metal grass screen,
remove the screen before removing the blower
housing. See Figure 9-36. Plastic grass screens
can be removed after the blower housing is
removed.
Figure 9-33. Removing the Spark Advance Module
(Applicable Models).
4. Remove the three (each side) hex flange screws
securing the outer baffles. Note the location of
any lifting strap and position of the two short
screws (one each side on bottom) for reassembly.
See Figure 9-34.
9
Figure 9-36. Removing Metal Grass Screen.
7. Remove the lower blower housing screw and
washer securing the rectifier-regulator ground
lead or grounding strap.
8. Two-Barrel Carburetor Models Only: Remove
the two screws securing the debris shield to the
blower housing. The wiring harness is attached
to the underside of shield. See Figure 9-37.
Figure 9-34. Note Location of Two Short Screws.
9.9
Section 9
Disassembly
Debris
Shield
Mounting
Screws
Figure 9-37. Debris Shield Details (Two-Barrel
Carburetor Model Shown).
9. Remove the remaining hex flange screws and
detach the blower housing. See Figure 9-38.
Figure 9-39. Removing Fasteners Holding Baffle
and Breather Cover.
2. Remove both inner baffles. See Figure 9-40.
10. Disconnect the plug from the key switch in the
blower housing if engine is so equipped.
Figure 9-40. Removing Inner Baffles.
3. Remove the two remaining screws holding the
breather cover to the crankcase. See Figure 9-40.
Figure 9-38. Removing Blower Housing.
Remove Inner Baffles and Breather Cover
The inner (valley) baffles are attached at one corner
using the same fasteners as the breather cover. See
Figure 9-39.
1. Remove the two hex flange screws securing the
inner baffles.
9.10
4. Pry under the protruding edge of the breather
cover with a screwdriver to break the RTV or
gasket seal. See Figure 9-41. Do not pry on the
sealing surfaces as it could cause damage
resulting in leaks. Most engines use a formed
gasket rather than RTV sealant.
Section 9
Disassembly
7. Remove the hex flange screw, breather reed
retainer and breather reed. See Figure 9-44.
Figure 9-41. Breaking Breather Cover Seal.
5. Remove the breather cover and gasket (if used).
See Figure 9-42.
Figure 9-44. Removing Breather Reed.
Remove Valve Covers
Three valve cover designs have been used. The
earliest type used a gasket and RTV sealant between
the cover and sealing surface of the cylinder head. The
second type had a black O-Ring installed in a groove
on the underside of the cover and may have metal
spacers in the bolt holes. The latest design uses a
brown O-Ring, and the bolt holes spacers are molded
in place.
1. Remove the four hex flange screws securing each
valve cover. Note the position of any attached
brackets or lifting straps.
Figure 9-42. Removing Breather Cover.
6. Remove the breather filter from chamber. See
Figure 9-43.
Figure 9-43. Removing Breather Filter.
2. Remove the valve covers, valve cover gaskets or
O-Rings and any brackets or lifting straps. Note
which side of the engine has the oil fill and or fuel
pump valve cover. See Figure 9-45.
Figure 9-45. Removing Valve Covers.
9.11
9
Section 9
Disassembly
Remove Ignition Modules
1. Disconnect the lead(s)* from each ignition
module. See Figure 9-46. *Modules for nonSMART-SPARK™ ignition systems have only one
kill lead.
3. Leave the wiring harness attached to the
manifold.
Aluminum
Intake
Manifold
Plastic Intake
Manifold
Figure 9-46. Disconnecting Leads from Ignition
Modules.
2. Rotate the flywheel so the magnet is away from
the modules.
3. Remove the mounting screws and ignition
modules. Note the position of ignition modules.
Two-Barrel
Intake Manifold
Figure 9-47. Position of SMART-SPARK™ Ignition
Module.
Remove Intake Manifold
1. Remove the four hex flange screws securing the
intake manifold to the cylinder heads. Note
which screws hold the wiring clamps.
2. Remove the intake manifold and the intake
manifold gaskets (aluminum intake manifolds) or
O-Rings (plastic intake manifolds). See Figure
9-48.
9.12
Figure 9-48. Removing Intake Manifold.
Section 9
Disassembly
Hex Flange Screw
Figure 9-49. Bolt Wiring Harness Detail.
Remove Spark Plugs
Hex Flange Nut
and Washer
1. Remove the spark plug from each cylinder head.
Figure 9-51. Removing Cylinder Head Fasteners.
Figure 9-50. Removing Spark Plugs.
2. Mark the position of the push rods as either
intake or exhaust and cylinder 1 or 2. Push rods
should always be reinstalled in the same
positions.
Remove Cylinder Heads and Hydraulic
Lifters
3. Carefully remove the push rods, cylinder heads
and head gaskets. See Figure 9-52.
NOTE: Cylinder heads are retained using either hex
flange screws or hex flange nuts and washers
on studs. Do not interchange or mix
components, as the cylinder heads may have
different machining, unique to each fastening
method.
1. Remove the four hex flange screws or hex nuts
and washers securing each cylinder head. See
Figure 9-51. Discard the screws or nuts and
washers once removed. Do not reuse. Studs (if
present) should only be removed if damaged or if
cylinder reconditioning is necessary. Once
removed, they must be replaced.
9.13
9
Section 9
Disassembly
Hex Flange Screw Style Mounting
Figure 9-53. Removing Hydraulic Lifter.
Stud and Hex Flange Nut Style Mounting
Figure 9-52. Removing Cylinder Head Assembly.
4. Remove the lifters from the lifter bores. Use a
Hydraulic Lifter Tool. Do not use a magnet to
remove lifters. Mark the lifters by location, as
either intake or exhaust and cylinder 1 or 2.
Hydraulic lifters should always be reinstalled in
the same position. See Figures 9-53 and 9-54.
Figure 9-54. Mark Position of Hydraulic Lifters.
NOTE: The exhaust lifters are located on the output
shaft side of the engine while the intake
lifters are located on the fan side of the
engine. The cylinder head number is
embossed on the outside of each cylinder
head. See Figure 9-55.
Figure 9-55. Match Marks on Cylinder Barrel and
Heads.
9.14
Section 9
Disassembly
Disassemble Cylinder Heads
1. Remove the two hex flange screws, rocker arm
pivots and rocker arms from the cylinder head.
See Figure 9-56.
3. Once the valve spring is compressed, remove the
following items. See Figures 9-58 and 9-59.
•
•
•
•
•
•
Valve spring keepers
Valve spring retainers
Valve springs
Valve spring caps
Intake and exhaust valves (mark position)
Valve stem seals (intake valve only)
Valve Seal
Figure 9-56. Removing Rocker Arms.
2. Compress the valve springs using a valve spring
compressor. See Figure 9-57.
Figure 9-59. Intake Valve Seal Location.
NOTE: These engines use valve stem seals on the
intake valves. Use a new seal whenever
valve is removed or if the seal is deteriorated
in any way. Never reuse an old seal.
4. Repeat the above procedure for the other
cylinder head. Do not interchange parts from one
cylinder head to the other.
Remove Grass Screen and Fan
Figure 9-57. Removing Valves with Valve Spring
Compressor.
Valve
1. Small metal retainers are typically attached on
three of the seven mounting posts for positive
retention of the plastic grass screen. Use a hookend tool next to the post and pull outward to
separate each of the small metal retainers. Then
unsnap the fan from the remaining mounting
posts. See Figure 9-60.
Keepers
Retainer
Cap
Spring
Figure 9-58. Valve Train Components.
9.15
9
Section 9
Disassembly
Figure 9-60. Removing Plastic Type Grass Screen.
2. Remove the four hex flange screws and fan. See
Figure 9-61.
Figure 9-62. Removing Flywheel Fastener Using
Strap Wrench.
2. Remove the hex flange screw and washer.
3. Use a puller to remove the flywheel from the
crankshaft. See Figure 9-63.
NOTE: Always use a flywheel puller to remove
the flywheel from the crankshaft. Do
not strike the crankshaft or flywheel, as
these parts could become cracked or
damaged. Striking the puller or
crankshaft can cause the crank gear to
move, affecting the crankshaft end play.
Figure 9-61. Removing Fan.
Remove Flywheel
1. Use a flywheel strap wrench or holding tool (see
Section 2) to hold the flywheel and loosen the hex
flange screw securing the flywheel to the
crankshaft. See Figure 9-62.
NOTE: Always use a flywheel strap wrench or
holding tool to hold the flywheel when
loosening or tightening the flywheel
screw. Do not use any type of bar or
wedge to hold the flywheel. Use of such
tools could cause the flywheel to become
cracked or damaged.
Figure 9-63. Removing Flywheel with a Puller.
4. Remove the woodruff key from the crankshaft.
Remove Stator and Backing Plates
1. Remove the four hex flange screws securing the
backing plates and stator wire bracket (if
equipped). See Figure 9-64. Remove the backing
plates and stator wire bracket.
9.16
Section 9
Disassembly
2. Locate the three splitting tabs that are cast into
the perimeter of the closure plate. Insert the drive
end of a 1/2" breaker bar between the top
splitting tab and the crankcase. Hold the handle
horizontal and pull toward you to break the RTV
seal. If necessary, pry at the bottom tabs also. See
Figures 9-67 and 9-68. Do not pry on the sealing
surfaces as this could cause leaks. Carefully pull
closure plate from crankcase.
Figure 9-64. Removing Backing Plates and Stator
Wire Bracket.
2. Remove the two hex head screws and stator. See
Figure 9-65. Note the routing of the stator lead in
the channel.
Figure 9-67. Location of Three Splitting Tabs.
9
Figure 9-65. Removing Stator.
Remove Closure Plate Assembly
1. Remove the ten hex flange screws securing the
closure plate to the crankcase. See Figure 9-66.
Figure 9-68. Breaking Seal on Top Splitting Tab.
Governor Gear Assembly
The governor gear assembly is located inside the
closure plate. If service is required, refer to the service
procedures under ‘‘Governor Gear Assembly’’ in
Section 10.
Oil Pump Assembly
The oil pump is mounted to the inside of the closure
plate. If service is required, refer to the service
procedures under ‘‘Oil Pump Assembly’’ in Section 10.
Figure 9-66. Removing the Ten Closure Plate
Fasteners.
9.17
Section 9
Disassembly
Remove Camshaft
1. Remove the camshaft and shim. See Figure 9-69.
Camshaft
Shim
Figure 9-71. Mark End Cap with Cylinder Number
Before Removal.
Figure 9-69. Removing Camshaft (Note Shim).
Remove Connecting Rods with Pistons
and Rings
1. Remove the two hex flange screws securing the
closest connecting rod end cap. Remove the end
cap. See Figure 9-70.
NOTE: The cylinders are numbered on the
crankcase. Use the numbers to mark each
end cap, connecting rod and piston for
reassembly. Do not mix end caps and
connecting rods.
Figure 9-72. Removing Piston/Connecting Rod
Assemblies.
Figure 9-70. Removing Connecting Rod Bolts.
NOTE: If a carbon ridge is present at the top of
either cylinder bore, use a ridge reamer
tool to remove the ridge before
attempting to remove the piston.
9.18
2. Carefully remove the connecting rod and piston
assembly from the cylinder bore. See Figure 9-72.
3. Repeat the above procedures for the other
connecting rod and piston assembly.
Section 9
Disassembly
Remove Crankshaft
1. Carefully pull the crankshaft from the crankcase.
See Figure 9-73. Note thrust washers and shims
if used.
Figure 9-75. Removing Governor Cross Shaft
Retainer (8 mm Shaft Design).
Figure 9-73. Removing Crankshaft.
2. Pull the cross shaft with small washer out
through the inside of the crankcase. See Figure
9-76.
Remove Governor Cross Shaft
1. Remove the hitch pin and plain washer, or the
retainer and nylon washer from the governor
cross shaft. See Figures 9-74 and 9-75.
9
Figure 9-76. Pulling Governor Cross Shaft.
Remove Flywheel End Oil Seal
1. Remove oil seal from crankcase. See Figure 9-77.
Figure 9-74. Removing Governor Cross Shaft Hitch
Pin (6 mm Shaft Design).
Figure 9-77. Removing Oil Seal.
9.19
Section 9
Disassembly
9.20
Section 10
Inspection and Reconditioning
Section 10
Inspection and Reconditioning
This section covers the operation, inspection, and
repair/reconditioning of major internal engine
components. The following components are not
covered in this section. They are covered in sections of
their own:
Air Cleaner, Section 4
Carburetor & External Governor, Section 5
Ignition, Charging & Electric Starter, Section 8
Clean all parts thoroughly. Only clean parts can be
accurately inspected and gauged for wear or damage.
There are many commercially available cleaners that
will quickly remove grease, oil, and grime from
engine parts. When such a cleaner is used, follow the
manufacturer’s instructions and safety precautions
carefully. Make sure all traces of the cleaner are
removed before the engine is reassembled and placed
into operation. Even small amounts of these cleaners
can quickly break down the lubricating properties of
engine oil.
Use an aerosol gasket remover, paint stripper, or
lacquer thinner to remove any old sealant. Apply the
solvent, allow time for it to work, and then brush the
surface with a brass wire brush. After the old sealant
is removed, clean the surface with isopropyl alcohol,
lacquer thinner, or aerosol electrical contact cleaner.
Do not scrape the surfaces, as any scratches, nicks, or
burrs can result in leaks. See Service Bulletin 252 for
further information.
Refer to A Guide to Engine Rebuilding (TP-2150-A)
for additional information. Measurement Guide
(TP-2159-B) and Engine Inspection Data Record
(TP-2435) are also available; use these to record
inspection results.
Automatic Compression Release (ACR)
Some engines are equipped with the optional
Automatic Compression Release (ACR) mechanism.
The ACR lowers compression at cranking speeds to
make starting easier.
Operation
The ACR mechanism consists of a flyweight, spring
and pivoting control pin assembly attached to the gear
on the camshaft. At cranking speeds (700 RPM or
lower), the control pin protrudes above the exhaust
cam lobe. This pushes the exhaust valve off its seat
during the first part of the compression stroke. The
reduced compression results in an effective
compression ratio of about 2:1 during cranking.
After starting, engine speed increases to over 700
RPM, and centrifugal force overcomes the force of the
flyweight spring. The flyweight moves outward,
pulling the arm of the control pin, so it pivots into the
‘‘run’’ position. The control pin no longer has any
effect on the exhaust valve and the engine operates at
full power.
When the engine is stopped, the spring returns the
flyweight lever and control pin assembly to the
compression release position ready for the next start.
Camshaft
Inspection and Service
Check the lobes of the camshaft for wear or damage.
See Section 1 for minimum lift specifications. Inspect
the cam gear for badly worn, chipped or missing teeth.
Replacement of the camshaft will be necessary if any
of these conditions exist.
Crankshaft
Inspection and Service
Inspect the gear teeth of the crankshaft. If the teeth are
badly worn, chipped, or some are missing,
replacement of the crankshaft will be necessary.
10.1
10
Section 10
Inspection and Reconditioning
Inspect the crankshaft bearing surfaces for scoring,
grooving, etc. Some engines have bearing inserts in
the crankshaft bore of the closure plate and/or
crankcase. Do not replace bearings unless they show
signs of damage or are out of running clearance
specifications. If the crankshaft turns easily and
noiselessly, and there is no evidence of scoring,
grooving, etc., on the races or bearing surfaces, the
bearings can be reused.
Inspect the crankshaft keyways. If they are worn or
chipped, replacement of the crankshaft will be
necessary.
Inspect the crankpin for score marks or metallic
pickup. Slight score marks can be cleaned with crocus
cloth soaked in oil. If the wear limits, as stated in
“Specifications and Tolerances” are exceeded, it will
be necessary to either replace the crankshaft or regrind
the crankpin to 0.25 mm (0.010 in.) undersize. If
reground, a 0.25 mm (0.010 in.) undersize connecting
rod (big end) must then be used to achieve proper
running clearance. Measure the crankpin for size,
taper, and out-of-round.
Procedure to Remove Crankshaft Plug:
1. Drill a 3/16" hole through the plug in the
crankshaft.
2. Thread a 3/4" or 1" long self-tapping screw with a
flat washer into the drilled hole. The flat washer
must be large enough to seat against the shoulder
of the plug bore. See Figure 10-2.
3. Tighten the self-tapping screw until it draws the
plug out of the crankshaft.
Procedure to Install New Plug:
1. Use a single cylinder camshaft pin, Kohler Part
No. 47 380 09-S as a driver and tap the plug into
the plug bore until it seats at the bottom of the
bore. Make sure the plug is tapped in evenly to
prevent leakage.
Self-Tapping Screw
Flat Washer
NOTE: If the crankpin is reground, visually check to
ensure that the fillet blends smoothly with
the crankpin surface. See Figure 10-1.
12345678
12345678
12345678
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Crankshaft
High Point from
Fillet Intersections
The Fillet Must
Blend Smoothly
with the Bearing
Journal Surface
Figure 10-2. Removing Crankpin Plug.
45°
Minimum
This Fillet Area
Must Be
Completely Smooth
Figure 10-1. Crankpin Fillets.
The connecting rod journal can be ground one size
under. When grinding a crankshaft, grinding stone
deposits can get caught in the oil passages, which
could cause severe engine damage. Removing the
crankpin plug when the crankshaft is ground provides
easy access for removing any grinding deposits that
may collect in the oil passages.
Use the following procedure to remove and replace
the plug.
10.2
Plug
Crankcase
Inspection and Service
Check all gasket surfaces to make sure they are free of
gasket fragments. Gasket surfaces must also be free of
deep scratches or nicks.
Inspect the main bearing (if so equipped) for wear or
damage (refer to Section 1, “Specifications, Tolerances,
and Special Torque Values”). Replace the crankcase
using a miniblock or short block as required.
Section 10
Inspection and Reconditioning
Check the cylinder bore wall for scoring. In severe
cases, unburned fuel can cause scuffing and scoring of
the cylinder wall. It washes the necessary lubricating
oils off the piston and cylinder wall. As raw fuel seeps
down the cylinder wall, the piston rings make metal to
metal contact with the wall. Scoring of the cylinder
wall can also be caused by localized hot spots
resulting from blocked cooling fins or from
inadequate or contaminated lubrication.
If the cylinder bore is badly scored, excessively worn,
tapered, or out-of-round, resizing is necessary. Use an
inside micrometer to determine the amount of wear
(refer to the “Specifications, Tolerances, and Special
Torque Values”, in Section 1), then select the nearest
suitable oversize of either 0.25 mm (0.010 in.) or
0.50 mm (0.020 in.). Resizing to one of these oversizes
will allow usage of the available oversize piston and
ring assemblies. First, resize using a boring bar, then
use the following procedures for honing the cylinder.
NOTE: Kohler pistons are custom-machined to
exacting tolerances. When oversizing a
cylinder, it should be machined exactly
0.25 mm (0.010 in.) or 0.50 mm (0.020 in.)
over the new diameter (Section 1). The
corresponding oversize Kohler replacement
piston will then fit correctly.
3. When the bore is within 0.064 mm (0.0025 in.) of
the desired size, remove the coarse stones and
replace them with burnishing stones. Continue
with the burnishing stones until the bore is
within 0.013 mm (0.0005 in.) of the desired size
and then use finish stones (220-280 grit) and
polish the bore to its final size. A crosshatch
should be observed if honing is done correctly.
The crosshatch should intersect at approximately
23°-33° off the horizontal. Too flat an angle could
cause the rings to skip and wear excessively, and
too steep an angle will result in high oil
consumption. See Figure 10-3.
NOTE: Some CH25-26 engines feature POWERBORE™ cylinders a special patented nickelsilicone plating process for increased power,
superior oil control, reduced exhaust
emission, and virtually permanent cylinder
life. POWER-BORE™ cylinders cannot be
resized or honed as described in the
following procedure. If a plated cylinder bore
is damaged or out of specification, use a new
miniblock or short block to repair the engine.
Use the following procedure for crankcases
with a cast iron sleeve.
Honing
While most commercially available cylinder hones
can be used with either portable drills or drill
presses, the use of a low speed drill press is preferred
as it facilitates more accurate alignment of the bore in
relation to the crankshaft crossbore. Honing is best
accomplished at a drill speed of about 250 RPM and
60 strokes per minute. After installing coarse stones in
hone, proceed as follows:
1. Lower hone into bore and after centering, adjust
so the stones are in contact with the cylinder
wall. Use of a commercial cutting-cooling agent
is recommended.
2. With the lower edge of each stone positioned
even with the lowest edge of the bore, start drill
and honing process. Move the hone up and down
while resizing to prevent the formation of
cutting ridges. Check the size frequently.
10
Figure 10-3. Cylinder Bore Crosshatch after
Honing.
4. After resizing, check the bore for roundness,
taper, and size. Use an inside micrometer,
telescoping gauge, or bore gauge to take
measurements. The measurements should be
taken at three locations in the cylinder – at the
top, middle, and bottom. Two measurements
should be taken (perpendicular to each other) at
each of the three locations.
Clean Cylinder Bore After Honing
Proper cleaning of the cylinder walls following boring
and/or honing is very critical to a successful overhaul.
Machining grit left in the cylinder bore can destroy an
engine in less than one hour of operation after a
rebuild.
10.3
Section 10
Inspection and Reconditioning
The final cleaning operation should always be a
thorough scrubbing with a brush and hot, soapy
water. Use a strong detergent that is capable of
breaking down the machining oil while maintaining a
good level of suds. If the suds break down during
cleaning, discard the dirty water and start again with
more hot water and detergent. Following the
scrubbing, rinse the cylinder with very hot, clear
water, dry it completely, and apply a light coating of
engine oil to prevent rusting.
Measuring Piston-to-Bore Clearance
Before installing the piston into the cylinder bore, it is
necessary that the clearance be accurately checked.
This step is often overlooked, and if the clearances are
not within specifications, engine failure will usually
result.
NOTE: Do not use a feeler gauge to measure pistonto-bore clearance – it will yield inaccurate
measurements. Always use a micrometer.
Use the following procedure to accurately measure
the piston-to-bore clearance:
1. Use a micrometer and measure the diameter of
the piston 6 mm (0.24 in.) above the bottom of the
piston skirt and perpendicular to the piston pin.
See Figure 10-4.
3. Piston-to-bore clearance is the difference
between the bore diameter and the piston
diameter (step 2 minus step 1).
Flywheel
Inspection
Inspect the flywheel for cracks and the flywheel
keyway for damage. Replace the flywheel if it is
cracked. Replace the flywheel, the crankshaft, and the
key if flywheel key is sheared or the keyway is
damaged.
Inspect the ring gear for cracks or damage. Kohler
does not provide the ring gear as a serviceable part.
Replace the flywheel if the ring gear is damaged.
Cylinder Head and Valves
Inspection and Service
After cleaning, check the flatness of the cylinder head
and the corresponding top surface of the crankcase,
using a surface plate or piece of glass and feeler gauge
as shown in Figure 10-5. The maximum allowable out
of flatness is 0.076 mm (0.003 in.).
6 mm (0.24 in.)
Measure 6 mm above the
Bottom of Piston Skirt at
Right Angles to Piston Pin
Figure 10-4. Measuring Piston Diameter.
2. Use an inside micrometer, telescoping gauge, or
bore gauge and measure the cylinder bore. Take
the measurement approximately 63.5 mm
(2.5 in.) below the top of the bore and
perpendicular to the piston pin.
10.4
Figure 10-5. Checking Cylinder Head Flatness.
Carefully inspect the valve mechanism parts. Inspect
the valve springs and related hardware for excessive
wear or distortion. Check the valves and valve seat
area or inserts for evidence of deep pitting, cracks, or
distortion. Check clearance of the valve stems in the
guides. See Figure 10-6 for valve details and
specifications.
Section 10
Inspection and Reconditioning
EXHAUST
VALVE
F
E
G
B
C
D
A
EXHAUST
INSERT
A
H
INTAKE
INSERT
D
B
Dimension
A
B
C
D
E
F
G
H
Seat Angle
Insert O.D.
Guide Depth
Guide I.D.
Valve Head Diameter
Valve Face Angle
Valve Margin (Min.)
Valve Stem Diameter
INTAKE VALVE
F
E
Intake
G
H
A
Exhaust
89°
36.987/37.013 mm (1.4562/1.4572 in.)
4 mm (0.1575 in.)
7.038/7.058 mm (0.2771/0.2779 in.)
33.37/33.63 mm (1.3138/1.3240 in.)
45°
1.5 mm (0.0591 in.)
6.982/7.000 mm (0.2749/0.2756 in.)
89°
32.987/33.013 mm (1.2987/1.2997 in.)
6.5 mm (0.2559 in.)
7.038/7.058 mm (0.2771/0.2779 in.)
29.37/29.63 mm (1.1563/1.1665 in.)
45°
1.5 mm (0.0591 in.)
6.970/6.988 mm (0.2744/0.2751 in.)
Figure 10-6. Valve Details.
Hard starting or loss of power accompanied by high
fuel consumption may be symptoms of faulty valves.
Although these symptoms could also be attributed to
worn rings, remove and check the valves first. After
removal, clean the valve heads, faces, and stems with a
power wire brush.
Then, carefully inspect each valve for defects such as a
warped head, excessive corrosion, or a worn stem
end. Replace valves found to be in bad condition. A
normal valve and valves in bad condition are shown
in the accompanying illustrations.
10.5
10
Section 10
Inspection and Reconditioning
Normal: Even after long hours of operation a valve
can be reconditioned and reused if the face and
margin are in good shape. If a valve is worn to where
the margin is less than 1/32" do not reuse it. The valve
shown was in operation for almost 1000 hours under
controlled test conditions.
Leakage: A poor grind on face or seat of valve will
allow leakage resulting in a burned valve on one side
only.
Bad Condition: The valve depicted here should be
replaced. Note the warped head; margin damaged
and too narrow. These conditions could be attributed
to excessive hours or a combination of poor operating
conditions.
Coking: Coking is normal on intake valves and is not
harmful. If the seat is good, the valve could be reused
after cleaning.
10.6
Section 10
Inspection and Reconditioning
Excessive Combustion Temperatures: The white
deposits seen here indicate very high combustion
temperatures, usually due to a lean fuel mixture.
Stem Corrosion: Moisture in fuel or from
condensation are the most common causes of valve
stem corrosion. Condensation occurs from improper
preservation during storage and when engine is
repeatedly stopped before it has a chance to reach
normal operating temperatures. Replace corroded
valves.
10
Gum: Gum deposits usually result from using stale
gasoline. Gum is a prevalent cause of valve sticking.
The cure is to ream the valve guides and clean or
replace the valves, depending on their condition.
Overheating: An exhaust valve subject to
overheating will have a dark discoloration in the area
above the valve guide. Worn guides and faulty valve
springs may cause this condition. Also check for
clogged air intake, and blocked fins when this
condition is noted.
10.7
Section 10
Inspection and Reconditioning
Valve Guides
If a valve guide is worn beyond specifications, it will
not guide the valve in a straight line. This may result in
burnt valve faces or seats, loss of compression, and
excessive oil consumption.
To check valve guide-to-valve stem clearance,
thoroughly clean the valve guide and, using a split-ball
gauge, measure the inside diameter of the guide. Then,
using an outside micrometer, measure the diameter of
the valve stem at several points on the stem where it
moves in the valve guide. Use the largest stem diameter
to calculate the clearance by subtracting the stem
diameter from the guide diameter. If the intake
clearance exceeds 0.038/0.076 mm (0.0015/0.0030 in.)
or the exhaust clearance exceeds 0.050/0.088 mm
(0.0020/0.0035 in.), determine whether the valve stem
or guide is responsible for the excessive clearance.
The maximum (I.D.) wear on the intake valve guide is
7.134 mm (0.2809 in.) while 7.159 mm (0.2819 in.) is the
maximum allowed on the exhaust guide. The guides
are not removable but can be reamed 0.25 mm
(0.010 in.) oversize. Valves with 0.25 mm oversize
stems must then be used.
If the guides are within limits but the valve stems are
worn beyond limits, install new valves.
Valve Seat Inserts
Hardened steel alloy intake and exhaust valve seat
inserts are press fitted into the cylinder head. The
inserts are not replaceable but can be reconditioned if
not too badly pitted or distorted. If cracked or badly
warped, the cylinder head should be replaced.
Recondition the valve seat inserts following the
instructions provided with the valve seat cutter being
used. A typical cutter is shown in Figure 10-7. The final
cut should be made with an 89° cutter as specified for
the valve seat angle in Figure 10-6. Cutting the proper
45° valve face angle as specified in Figure 10-6, and the
proper valve seat angle (44.5°, half of the full 89° angle),
will achieve the desired 0.5° (1.0° full cut) interference
angle where the maximum pressure occurs on the
outside diameters of the valve face and seat.
10.8
Valve Seat Cutter
Pilot
Figure 10-7. Typical Valve Seat Cutter.
Lapping Valves
Reground or new valves must be lapped in, to provide
proper fit. Use a hand valve grinder with a suction
cup for final lapping. Lightly coat the valve face with a
“fine” grade of grinding compound, then rotate the
valve on its seat with the grinder. Continue grinding
until a smooth surface is obtained on the seat and on
the valve face. Thoroughly clean the cylinder head in
soap and hot water to remove all traces of grinding
compound. After drying the cylinder head, apply a
light coating of SAE 10 oil to prevent rusting.
Intake Valve Stem Seal
These engines use valve stem seals on the intake
valves. Always use a new seal when the valves are
removed from the cylinder head. The seals should also
be replaced if deteriorated or damaged in any way.
Never reuse an old seal.
Pistons and Rings
Inspection
Scuffing and scoring of pistons and cylinder walls
occurs when internal engine temperatures approach
the welding point of the piston. Temperatures high
enough to do this are created by friction, which is
usually attributed to improper lubrication and/or
overheating of the engine.
Normally, very little wear takes place in the piston
boss-piston pin area. If the original piston and
connecting rod can be reused after new rings are
installed, the original pin can also be reused but new
piston pin retainers are required. The piston pin is
included as part of the piston assembly – if the pin
boss in the piston or the pin are worn or damaged, a
new piston assembly is required.
Section 10
Inspection and Reconditioning
Ring failure is usually indicated by excessive oil
consumption and blue exhaust smoke. When rings
fail, oil is allowed to enter the combustion chamber
where it is burned along with the fuel. High oil
consumption can also occur when the piston ring end
gap is incorrect because the ring cannot properly
conform to the cylinder wall under this condition. Oil
control is also lost when ring gaps are not staggered
during installation.
Detonation damage occurs when a portion of the fuel
charge ignites spontaneously from heat and pressure
shortly after ignition. This creates two flame fronts
which meet and explode to create extreme hammering
pressures on a specific area of the piston. Detonation
generally occurs from using low octane fuels.
When cylinder temperatures get too high, lacquer and
varnish collect on pistons causing rings to stick, which
results in rapid wear. A worn ring usually takes on a
shiny or bright appearance.
Preignition or ignition of the fuel charge before the
timed spark can cause damage similar to detonation.
Preignition damage is often more severe than
detonation damage. Preignition is caused by a hot
spot in the combustion chamber from sources such as
glowing carbon deposits, blocked cooling fins, an
improperly seated valve, or wrong spark plug(s).
Scratches on rings and pistons are caused by abrasive
material such as carbon, dirt, or pieces of hard metal.
See Figure 10-8 for some common types of piston and
ring damage.
Stuck, Broken Rings
Abrasive Scratched Rings
Overheated or Deteriorated Oil
Scored Piston and Rings
10
Figure 10-8. Common Types of Piston Damage.
10.9
Section 10
Inspection and Reconditioning
Replacement pistons are available in STD bore size,
and in 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.)
oversize. Replacement pistons include new piston ring
sets and new piston pins.
Replacement ring sets are also available separately for
STD, 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.)
oversize pistons. Always use new piston rings when
installing pistons. Never use old rings.
Some important points to remember when servicing
piston rings:
1. The cylinder bore must be deglazed before
service ring sets are used.
2. If the cylinder bore does not need reboring and if
the old piston is within wear limits and free of
score or scuff marks, the old piston may be
reused.
3. Remove the old rings and clean up the grooves.
Never reuse old rings.
4. Before installing the new rings on the piston,
place the top two rings, each in turn, in its
running area in the cylinder bore and check the
end gap. (See Figure 10-9.) Compare the ring gap
to the specifications listed in Section 1.
Figure 10-10. Measuring Piston Ring Side
Clearance.
Install New Piston Rings
To install new piston rings, proceed as follows:
NOTE: Rings must be installed correctly. Ring
installation instructions are usually included
with new ring sets. Follow instructions
carefully. Use a piston ring expander to
install rings (see Figure 10-11). Install the
bottom (oil control) ring first and the top
compression ring last. Refer to Figure 10-12.
Piston Ring
Piston Ring
Expander
Figure 10-11. Installing Piston Rings.
Figure 10-9. Measuring Piston Ring End Gap.
5. After installing the new compression (top and
middle) rings on the piston, check the piston-toring side clearance. Compare the clearance to
specifications listed in Section 1. If the side
clearance is greater than specified, a new piston
must be used. Refer to Figure 10-10.
10.10
Section 10
Inspection and Reconditioning
Piston Ring
Dykem
Stripe
End Gap
Identification
Mark
Service replacement connecting rods are available in
STD crankpin size and 0.25 mm (0.010 in.) undersize.
The 0.25 mm (0.010 in.) undersized rod can be
identified by the drilled hole located in the lower end
of the rod shank. Always refer to the appropriate parts
information to ensure that correct replacements are
used.
Hydraulic Lifters
Piston
Top
Compression
Ring
Center
Compression
Ring
Rails
Oil Control Ring
(Three-piece)
Expander
Figure 10-12. Piston Ring Installation.
1. Oil Control Ring (Bottom Groove): Install the
expander and then the rails. Make sure the ends
of expander are not overlapped.
2. Middle Compression Ring (Center Groove):
Install the center ring using a piston ring
installation tool. Make sure the “identification”
mark is up or the dykem stripe (if contained) is to
the left of the end gap.
3. Top Compression Ring (Top Groove): Install the
top ring using a piston ring expender. Make sure
the “identification” mark is up or the dykem
stripe (if contained), to the left of the end gap.
Connecting Rods
Offset, stepped-cap connecting rods are used in all
these engines.
Inspection and Service
Check the bearing area (big end) for excessive wear,
score marks, running and side clearances (refer to
Section 1, “Specifications, Tolerances, and Special
Torque Values”). Replace the rod and cap if scored or
excessively worn.
Inspection
Check the base surface of the hydraulic lifters for wear
or damage. If the lifters need to be replaced, apply a
liberal coating of Kohler lubricant (see Section 2) to
the base of each new lifter before it is installed.
“Bleeding” the Lifters
To prevent a possible bent push rod or broken rocker
arm, it is important to “bleed” any excess oil out of the
lifters before they are installed.
1. Cut a 50-75 mm (2-3 in.) piece from the end of an
old push rod and chuck it in a drill press.
2. Lay a rag or shop towel on the table of the drill
press and place the lifter, open end up, on the
towel.
3. Lower the chucked push rod until it contacts the
plunger in the lifter. Slowly “pump” the plunger
two or three times to force the oil out of the feed
hole in the side of the lifter.
Closure Plate Assembly
Inspection
Inspect the oil seal in the closure plate and remove it if
it is worn or damaged. Refer to ‘‘Install Closure Plate
Oil Seal’’ in Section 11 for new oil seal installation.
Inspect the main bearing surface for wear or damage
(refer to Section 1, “Specifications, Tolerances, and
Special Torque Values”). Replace the closure plate
assembly if required.
Governor Gear Assembly
Inspection
Inspect the governor gear teeth. Replace the gear if it
is worn, chipped, or if any teeth are missing. Inspect
the governor weights. They should move freely in the
governor gear.
10.11
10
Section 10
Inspection and Reconditioning
Disassembly
The governor gear must be replaced once it is
removed from the closure plate.
NOTE: The governor gear is held onto the shaft by
small molded tabs in the gear. When the gear
is removed from the shaft, these tabs are
destroyed and the gear must be replaced.
Therefore, remove the gear only if absolutely
necessary.
1. Remove the regulating pin and governor gear
assembly. See Figure 10-13.
Reassembly
1. Install the locking tab thrust washer on the
governor gear shaft with the tab down.
2. Position the regulating pin within the governor
gear/flyweight assembly and slide both onto the
governor shaft.
Oil Pump Assembly
Disassembly
1. Remove the two hex flange screws.
2. Remove the oil pump assembly from the closure
plate.
3. Remove the oil pump rotor.
4. Remove the oil pickup by unhooking the locking
clip, and pulling it free from the oil pump body.
5. If the relief valve is like that shown in Figure
10-15, drive out the pin to remove the oil pressure
relief valve piston and spring. Refer to the
following inspection and reassembly procedures.
Figure 10-13. Removing Governor Gear.
2. Remove the locking tab thrust washer located
under the governor gear assembly.
If the relief valve is a one-piece style, staked to the
oil pump housing (See Figure 10-16) removal
should not be attempted, nor is internal servicing
possible. If a problem with the relief valve is
encountered, the oil pump should be replaced.
3. Carefully inspect the governor gear shaft and
replace it only if it is damaged. After removing
the damaged shaft, press or lightly tap the
replacement shaft into the closure plate to the
depth shown in Figure 10-14.
Gear Shaft
34.0 mm (1.3386 in.)
33.5 mm (1.3189 in.)
19.40 mm (0.7638 in.)
Relief Valve
Pickup
Figure 10-15. Oil Pump, Oil Pickup, and Relief Valve
(Original Style).
Figure 10-14. Governor Shaft Press Depth.
10.12
Section 10
Inspection and Reconditioning
3. Install the rotor.
4. Install the oil pump body to the closure plate and
secure with the two hex flange screws. Torque
the hex flange screws as follows:
a. Install fastener into location No. 1 and lightly
tighten to position pump.
b. Install fastener into location No. 2 and fully
torque to the recommended value.
Relief Valve
Pickup
Figure 10-16. Oil Pump, Oil Pickup, and One-Piece
Relief Valve (Later Style).
c. Torque fastener in location No. 1 to the
recommended value.
Inspection
Inspect the oil pump housing, gear, and rotors for
nicks, burrs, wear, or any visible damage. If any parts
are worn or damaged, replace the oil pump.
Inspect the oil pressure relief valve piston. It should be
free of nicks or burrs.
Check the spring for wear or distortion. The free
length of the spring should be approximately 47.4 mm
(1.8 in.). Replace the spring if it is distorted or worn.
See Figure 10-17.
Oil Pump Torque Sequence
First Time Installation:10.7 N·m (95 in. lb.)
All Reinstallations:
6.7 N·m (60 in. lb.)
5. After torquing, rotate the gear and check for
freedom of movement. Make sure there is no
binding. If binding occurs, loosen the screws,
reposition the pump, retorque the hex flange
screws and recheck the movement.
Piston
Spring
Roll Pin
Figure 10-17. Oil Pressure Relief Valve Piston and
Spring.
Reassembly
1. Install the pressure relief valve piston and spring.
2. Install the oil pickup to the oil pump body.
Lubricate the O-Ring with oil and make sure it
remains in the groove as the pickup is being
installed.
10.13
10
Section 10
Inspection and Reconditioning
Governor Cross Shaft Oil Seal
If the governor cross shaft seal is damaged and/or
leaks, replace it using the following procedure.
Remove the oil seal from the crankcase and replace it
with a new one. Install the new seal to the depth
shown in Figure 10-18 using a seal installer.
2.0 mm (0.0787 in.)
Governor Cross
Shaft Seal
Figure 10-18. Installing Cross Shaft Oil Seal.
10.14
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Section 12
Clutch
Section 12
Clutch
Clutch
General
Some engines are equipped with a “wet” disc type clutch. See Figure 12-1 for exploded view of clutch.
Shifting Lever
Nameplate
Gasket
Shaft
(Yoke)
Seal
Clutch
Housing
Yoke
Key
Roll Pin
Adjusting
Ring
Driven
Member
Oil Seal
Power
Shaft
Ball Bearing
Snap Ring
Pressure
Plate
Retaining
Rings
Pilot Bearing
Release
Sleeve
Bearing Release
Assembly
Clutch Assembly
12
Clutch
Assembly
Adjusting
Lock
Figure 12-1. Wet Type Clutch - Exploded View.
12.1
Section 12
Clutch
Service
On this type, an oil “splash” type lubrication system is
used. The proper oil level must be maintained to
provide efficient lubrication. The oil should be
changed after each 100 hours of operation. When
refilling, use 0.47 L (1 pt.) of motor oil of proper
viscosity. See chart below.
Reconditioning
Drain the oil, remove the nameplate, and use the
following procedure.
Temperature
SAE Viscosity
Above 10°C (50°F)
S A E 30
-17.8°C (0°F) to 10°C (50°F)
S A E 20
1. Remove capscrews (2) from clutch yoke and
remove spacers.
Below -17.8°C (0°F)
S A E 10
2. Remove cross shaft.
Adjustment
Slight readjustment may be needed after a few hours
on a new clutch to accommodate normal run-in wear.
Firm pressure should be required to engage clutch
(40-45 pounds pull at lever handle). Readjust if clutch
slips and overheats, or if clutch handle jumps out after
engagement. Use the following procedure:
1. Release clutch and remove nameplate. Using a
large screwdriver, turn adjusting ring clockwise,
one notch at a time, until firm pressure is
required to engage clutch. See Figure 12-2.
Adjusting ring is spring loaded and does not
have to be loosened before adjustment is made.
Do not attempt to pry or force spring lock away
from the ring.
Adjustment
Ring
Spring
Lock
Figure 12-2. Adjusting Clutch.
12.2
2. After adjustment is made, engage clutch and
check to make sure rollers go over center to lock
the unit in engaged position and prevent
releasing under load. If trouble persists after
readjustment, clutch reconditioning is indicated.
3. Remove housing bolts (4) and slide housing off.
4. Loosen bolts securing clutch assembly to
crankshaft, then remove locking screw.
5. Pull clutch assembly off.
6. To replace clutch, simply turn adjusting collar off
and remove plate.
Reverse procedure for reassembly. Adjust and
lubricate following previous instructions.
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ENGINE APPLICATION GUIDE
SEEK
the innovation.™
demand
THE POWER.™
Introduction
At Kohler, we are proud of the fact that we make fine four-cycle, air- and liquid-cooled engines. We strive to keep
ahead of changing requirements and offer the latest “state-of-the-art” engines, which were developed to meet
stringent regulations mandating low emissions. All Command, OHC/Triad, Kohler Aegis™, and Courage engines
have been certified to meet applicable U.S. and California Emission Control Regulations for SORE (Small OffRoad Engines), or Class 1 LSI (Large Spark Ignited) regulations as applicable. Our goal is also to reduce
operational noise, and provide the end user a low maintenance product. Our wide range of quality built engines,
from 4 to 29 horsepower, provide you a choice of power that best fits your application and performance
requirements.
And when you put one of our engines in your equipment, the Kohler name and reputation for quality go along with
it. Naturally, we want to make sure our engine and your equipment form a combination that will be a credit to both
of us.
That is why we have produced this Engine Application Guide. It gives you an organized, coordinated approach to
selecting and installing a Kohler Engine in your specific application. In following the procedures explained here,
you can be sure that you are considering most of the practical aspects of engine application.
We’ve divided the guide into five sections:
•
Selecting the Right Engine ............................................................................................................... Section 1
•
Properly Connecting the Engine to the Load .................................................................................... Section 2
•
Properly Installing the Engine ........................................................................................................... Section 3
•
Testing the Installation ...................................................................................................................... Section 4
•
Technical Guidelines ........................................................................................................................ Section 5
This guide is meant to be an easy-to-use tool, something you’ll turn to when your new ideas are ready to go onto
the drawing board. We hope it makes your job easier and will help you build the best possible product for your
customers.
Feel free to call your Kohler Engine representative if you have any questions not answered in this book or wish to
discuss any of the suggestions offered within the book.
Safety Note:
2
When planning an installation, keep safety in mind. Refer to the “Safety Precautions” on page 3
for some important reminders.
Read Before Proceeding
WARNING
WARNING
Explosive Fuel can cause fires and
severe burns.
Explosive Gas can cause fires and
severe acid burns.
Stop engine before filling fuel tank.
Charge battery only in a well
ventilated area. Keep sources of
ignition away.
Explosive Fuel!
Gasoline is extremely flammable
and its vapors can explode if
ignited. Store gasoline only in
approved containers, in well
ventilated, unoccupied buildings,
away from sparks or flames. Do not
fill the fuel tank while the engine is
hot or running, since spilled fuel
could ignite if it comes in contact
with hot parts or sparks from
ignition. Do not start the engine
near spilled fuel. Never use
gasoline as a cleaning agent.
WARNING
Accidental Starts can cause severe
injury or death.
Explosive Gas!
Batteries produce explosive
hydrogen gas while being charged.
To prevent a fire or explosion,
charge batteries only in well
ventilated areas. Keep sparks, open
flames, and other sources of
ignition away from the battery at all
times. Keep batteries out of the
reach of children. Remove all
jewelry when servicing batteries.
Before disconnecting the negative
(-) ground cable, make sure all
switches are OFF. If ON, a spark
will occur at the ground cable
terminal which could cause an
explosion if hydrogen gas or
gasoline vapors are present.
WARNING
Disconnect and ground spark plug
lead before servicing.
Accidental Starts!
Disabling engine. Accidental
starting can cause severe injury
or death. Before working on the
engine or equipment, disable the
engine as follows: 1) Disconnect the
spark plug lead(s). 2) Disconnect
negative (-) battery cable from
battery.
Rotating Parts can cause severe
injury.
Stay away while engine is in
operation.
Rotating Parts!
Keep hands, feet, hair, and clothing
away from all moving parts to
prevent injury. Never operate the
engine with covers, shrouds, or
guards removed.
WARNING
Hot Parts can cause severe burns.
Do not touch engine while operating
or just after stopping.
Hot Parts!
Engine components can get
extremely hot from operation. To
prevent severe burns, do not touch
these areas while the engine is
running—or immediately after it is
turned off. Never operate the
engine with heat shields or guards
removed.
WARNING
Carbon Monoxide can cause
severe nausea, fainting or death.
Do not operate engine in closed or
confined area.
Lethal Exhaust Gases!
Engine exhaust gases contain
poisonous carbon monoxide.
Carbon monoxide is odorless,
colorless, and can cause death if
inhaled. Avoid inhaling exhaust
fumes, and never run the engine in
a closed building or confined area.
CAUTION
Electrical Shock can cause injury.
Do not touch wires while engine is
running.
Electrical Shock!
Never touch electrical wires or
components while the engine is
running. They can be sources of
electrical shock.
3
Section 1
Selecting the Right Engine
Selecting the Right Engine
When you start designing the new piece of power
equipment, you probably have some notion of what
size engine will be needed. Keep in mind, however,
that there is more to consider in the selection process
than just picking an engine based on power curves.
The engine selected must be capable of meeting the
demands of the equipment under all of the conditions
in which the equipment will have to operate! The
engine must be a good match to ensure success
of the design and user satisfaction.
Before the right engine can be selected, it is essential
to know what the load or power requirement of the
driven equipment is and what the operating
requirements are. These are covered in detail later.
Why Not Just Select From Power Curves?
All manufacturers of air-cooled engines in the United
States use the Society of Automotive Engineers (SAE)
test codes to rate their engines. Engines currently
produced by Kohler Co. are rated under SAE test code
J1940. Tests are based on sea level operation
(barometric pressure of 29.92 inches of mercury or
760 mm). The J1940 test establishes a correlation
temperature of 77°F (25°C). The Horsepower/Torque
power curves shown and in our sales literature, are
Gross Horsepower generated under laboratory
conditions. When engines are shipped with the
required air cleaner and approved, emission compliant
exhaust systems they will generate Net Horsepower;
this will be approximately 15% below the gross curve.
Available Horsepower calculations should be based on
a net output figure. Operating at temperatures or
elevations different from the test standards will change
the horsepower output. This will be figured in later,
along with other factors, which influence engine
horsepower. The performance of an engine under test
lab conditions is plotted on power data curves, such as
those shown in Figure 1-1 for the Kohler 11, 13, and 15
HP Command engines. Power curves are available for
all Kohler engines. In some publications, only the
torque curves are shown, as in the sample in Figure
1-2. Torque is a turning or twisting motion that
produces rotation or torsion perpendicular to the drive
shaft. An accurate comparison of Torque Output at the
desired running speed is particularly critical when
replacing older non-emission-compliant, L-head
engines with newer OHV engines. While both may
generate 25 HP at 3600 RPM, the 1000 cc L-head
engine will produce significantly more Torque at 2400
RPM than a 750 cc OHV engine.
Figure 1-1. Power Curve Example (Command 11,
13, and 15 HP).
4
Section 1
Selecting the Right Engine
41
39
38
37
36
35
34
33
2000
1800
2400
2200
2800
2600
3200
3000
3600
3400
Torque (Foot Pounds)
40
31
Revolutions Per Minute
Figure 1-2. Torque Curve Example.
If you want to figure the brake horsepower of an
engine when only the torque curve is given, multiply
the torque (foot pounds) by the time element which is
the RPM (Revolutions Per Minute), and divide this by
the constant, 5252. The formula is expressed below:
Torque x RPM
5252
= HP
Using the formula and the torque curve of the engine
shown in Figure 1-2, we would arrive at the following
horsepower rating.
34 (ft. lb. torque) x 3600 RPM
= 23.3 HP
5252 (constant)
It would be great if we could just use the power curve
data to select an engine. However, there are other
factors to be considered. Engines are rated at
maximum allowable RPM (which is 3600 RPM on all
Command engines except the CH6 which is rated at
4000 RPM) and wide-open throttle (WOT). Continuous
operation under such conditions could adversely affect
the engine life. This and other operating conditions to
consider are as follows.
NOTE: The following are the normal, industryaccepted operational factors, which apply to
all makes of engines.
Operational Factors
Duty Cycle: If the engines is to be operated at
constant speed and load such as to power a
generator or pump, use an 80% power factor. For
intermittent duty applications with 50% or less duty
cycle, use an 85% factor. Tractors and tillers are
intermittent duty applications.
Altitude Effect: Air needed for combustion becomes
less dense as altitude increases. This results in a
proportionate decrease in engine horsepower. For
every 1000 foot (305 m) increase above sea level,
calculate a 3.5% decrease in available horsepower. At
altitudes higher than 5000 ft (1524 m) for all models
except CS engines which is 6000 ft (1829 m) above sea
level, special main fuel jets are required for some
carburetors. Refer to the chart on page 6.
5
Section 1
Selecting the Right Engine
100%
96.5
3.5% Drop (for every 1000' above sea level)
93.0
7.0 Drop
10.5 Drop
89.5
14.0 Drop
86.0
NOTE: Engines operating at altitudes
5000 ft (1524 m) all models
except CS engines which is
6000 ft (1829 m) and higher, may
need a special high altitude
main fuel jet in carburetor.
17.5 Drop
82.5
21.0 Drop
79.0
24.5 Drop
75.5
72.0
Sea
1000'
Level
Chart: Altitude Effect on HP.
2000'
3000'
4000'
Temperature Effect: 1% decrease in HP for every 10°
over 77°F (25°C).
Transmission Efficiencies: The fourth factor to
consider is how the engine will be connected to the
load. Other than using direct couplings, such as a
mower blade attached directly to the crankshaft of an
engine, there are normal losses of power. Not all of the
power is transmitted by other drives. There are six
basic drive systems, which are listed as follows:
1. Direct Shaft
2. Belt & Pulley
5000'
6000'
7000'
28.0 Drop
8000'
Refer to the chart below for efficiency values for some
common transmission methods.
Transmission Efficiencies Chart
Transmission
Direct Coupled
Efficiency (Typical)
100%
V-belt
Roller Chains
Spur Gears
Gear Reductions
Pumps
96-98%
95-97%
96%
(Contact Manufacturer)
50-80%
3. Chain & Sprocket
Some important points regarding drives are described
in Section 2 of this guide.
4. Friction Drive
Matching the Engine to the Load
5. Gear Drives
6. Electric Clutch (which apply instant load)
6
The engine selected must be sized for the worst
possible operating conditions. An undersize engine, no
matter how carefully it is installed and operated, is
likely to cause problems. Keep in mind the four factors
described earlier when calculating usable horsepower.
The load requirement may be available from the drive
equipment manufacturer if the engine is to power such
equipment. If it’s a new application, be cautious when
using a “trial-and-error” method of load determination.
If you need help, contact your Kohler Engine
representative. They have forms and the experience to
assist you in selecting the right engine.
Section 1
Selecting the Right Engine
How to Calculate Usable Horsepower
Example 1: As an example of how to calculate the
actual horsepower requirements, let’s say you have
designed a unique new tiller and estimate the load
requirement to be 4 HP at 3600 RPM. Don’t forget,
however, to apply the four industry-accepted factors
described earlier which are:
1. Duty - This will be an intermittent duty application
= 85% available.
2. Altitude - Maximum to be 2000 feet above sea
level. Factor 3.5% for every 1000 feet above.
2(000) x 3.5 = 7% decrease or = 93% available
3. Temperature - Maximum ambient should not
exceed 95°F. On engines rated under J1940 test
code, figure 1% decrease for every 10°F over
77°F (25°C). In this case 2% factor = 98%
available.
4. Transmission - This application will use chain
drive, which is listed at 95-97% in the chart. Using
the lowest = 95% available.
Applying these factors, the actual horsepower
requirement is arrived at using the following formula:
4
4 HP Estimated Load
= 5.435 actual
=
HP Required
.85 x .93 x .98 x .95
.736
A good match for this particular application would be
the Kohler Command CH6. It would have reserve
power and many other features to fit the job.
3. Temperature - 1% loss for every 10°F above
77° = 4% = 96% available.
4. Transmission - V-belt at midpoint range = 97%
available.
The calculation for this application is as follows:
8 HP Estimated Load
8
=
.80 x 89.5 x .96 x .97
.6667
11.999 or 12 HP
= engine actually
required
A good choice for this second example would be a
Kohler Command CH13 for a little extra reserve power.
Example 3: What about a lower speed application that
calls for a load of 8 HP at 2800 RPM? The duty cycle
will be intermittent (85%), temperature below 77°F (no
factor), the altitude about 500 feet above sea level (3.5
per 1000 feet divided by 2 = 1.75 loss or 98.25 factor),
and the load will be belt driven (97% factor) off a
horizontal shaft. Using these factors, let’s calculate
what the actual power requirement will be, using the
HP formula.
8 HP Estimated Load
=
.85 x 1 x .9825 x .97
8
.810
= 9.88 HP actual
Checking the power curves, we find that a CH11 would
do the job. It produces 19.25 foot pounds of torque at
2800 RPM. Using the torque-to-horsepower formula,
this indicates 10.26 HP is available (19.25 x 2800 =
53900 ÷ 5252 = 10.26).
Example 2: As another example, let’s figure a
constant duty fan application. The fan manufacturer’s
specs call for an 8 HP load demand at 3600 RPM.
This unit will be operated at an altitude of 3000 feet
above sea level and the maximum operating
temperature of 115°F. Drive will be V-belt. The factors
will be:
1. Duty - Constant speed and load = 80% available.
2. Altitude - 3.5% loss for every 1000 feet above =
10.5 loss = 89.5% available.
7
Section 2
Properly Connecting the Engine to the Load
Properly Connecting the Engine to the
Load
This section contains some recommendations and
precautions relating to connecting the engine to the
load. The more common methods are V-belt, chain
drive, direct coupled, and universal joint. The
crankshafts on Kohler engines rotate
counterclockwise when viewed from the rear or PTO
side of the engine (side opposite cooling air intake).
Crankshaft End Thrust Note:
If anything is fitted to the engine that imposes an end
load on the crankshaft (such as an automotive type
clutch), make sure that the maximum allowable values
for the crankshaft load are not exceeded. Check with
the manufacturer for details of the operating end thrust
of their equipment.
Important Note! Engines with ball bearings can
absorb hammering forces imposed by drives in line
with the crankshaft better than engines with sleevetype bearings or with machined bearing surfaces.
Contact your Kohler Engine representative if
considering using engines in applications requiring
tight, interference fit drives.
V-belt Drives
Using larger pulleys can ease belt load on crankshaft
and bearings. Larger pulleys require less belt tension
to transmit the same horsepower. They also permit the
use of belts with smaller cross-section, which improves
efficiencies. Check the belt supplier’s specifications for
help in designing the V-belt drive. Generally, A-type
belts and pulleys with outer diameters of at least
3.6 in. (90 mm) or B-type pulleys with outer diameters
of 4.8 in. (120 mm), are used on Kohler engine
applications. See belt selection data in Section 5,
Technical Guidelines.
V-belts must be kept perfectly aligned between the
engine and load. Belt tension should be set to the belt
supplier’s specifications which in general is about
1/64 in. (0.396 mm) deflection per inch at midpoint in
the span. Misalignment contributes to shaft stress and
premature wear on belts. Refer to V-belt Drive data in
Section 5 for tension formula.
To avoid stressing the crankshaft and bearings, keep
the pulley from extending beyond the end of the shaft.
(See Figure 2-2.)
Do Not Extend
Pulley Beyond
End of Shaft
Pulley
Crankshaft
Figure 2-2. Pulley Location on Shaft.
When a pulley is installed on a front PTO extension,
make sure the pulley does not restrict cooling air
entering the air intake or grass screen. Keep it away
from the screen, but not too far where it would place
stress on the crankshaft and front bearing. A minimum
clearance of 2 in. (50.8 mm) is needed for a 4 in.
(101.6 mm) diameter pulley. Engine application testing
is required if this clearance is not available, or if the
pulley diameter is exceeded.
Pulley too
Close to Air Intake
V-Belt
Drive
Pulley
Arm
Driven Pulley
Idler*
*Inside location preferred.
Figure 2-1. Pulley-Drive System.
8
Restricts
Air Intake
Figure 2-3. Front PTO Pulley.
Section 2
Properly Connecting the Engine to the Load
OEM Sizing
Where the spline drive is the primary means of power
transmission sizing of the drive system should be
restricted as follows:
Top View
Engine
Pulley
Keep Belt &
Pulleys Aligned
to Avoid Stress
V-Belt
Load
Driven
Pulley
Figure 2-4. Keep Pulleys and Belts Aligned.
9 Tooth - Max 15 HP Engine Output
11 Tooth - Max 20 HP Engine Output
13 Tooth - Max 35 HP Engine Output
In engine families where the model range crosses
these limits it is advisable to select the larger sized
drive system.
Flexible Couplings are preferred for most directcoupled applications because they tolerate some
minor axial and angular misalignment. Even with
flexible couplings, however, it is important to maintain
the best possible alignment to reduce the load on the
coupling and/or to avoid strain on the crankshafts and
bearings.
Direct Coupled Drives
In some applications the engine will be direct coupled
to the load. This type is 100% efficient; however, the
engine and driven equipment must be rigidly mounted
to maintain proper and accurate alignment.
Spline Drives
We offer a variety of crankshafts with a female spline
insert and an adapter plate for hydraulic pump
mounting. Because of the extremely high torque
pulses generated by a 1 or 2 cylinder, 4 cycle engine, it
is not possible to size spline drives on the same basis
as other power sources, e.g. electric motors. High
torque pulses generate extreme face pressures, which
will result in fretting damage if not continuously
lubricated. For this reason we recommend the
following practices be adopted to ensure proper
service life and customer satisfaction.
OEM Initial Assembly
Lubricate the entire spline assembly with GN Assembly
paste (Dow Corning) or equivalent (Kohler Part No.
25 357 12-S).
OEM Installation
Install the engine in such a manner to permit
relubrication of the spline every 500 hours, sooner
under dusty conditions. The equipment owner’s
manual should emphasize this.
Axial Misalignment
Angular Misalignment
Correct Alignment
Figure 2-5. Flexible Coupling.
Belt Loading via Crankshaft
There are many components to be considered in a belt
drive system. In order to perform a thorough analysis,
full documentation should be provided to Kohler Co.
Application Engineering Department. The following
guidelines should be observed.
A. Where the centerline of the main drive pulley is
more than 2.5 in. (65 mm) from the cylinder block,
a belt load review is required by Kohler Co.
B. Where an electric clutch is used to drive a
commercial mower deck, a PTO bearing insert is
required.
C. Commercial Mowers utilizing engines of 18 HP &
over, should use crankshafts of 1.125 in. (28.575
mm) diameter or greater.
9
Section 2
Properly Connecting the Engine to the Load
Universal Joints are required in some arrangements
when the engine is not in line with the driven unit.
Follow the drive manufacturer’s recommendations
regarding installation and maintenance.
Driven Unit
Figure 2-6. Universal Joints.
Engine
Three-Bearing Housing. When this type of housing is
used, make certain the mounting faces on both the
housing and the engine are perfectly true and square –
and that the bearing is in perfect alignment with engine
bearings. Use dial indicators to determine alignment
and prevent shaft “bending” problems.
Mounting Face
Mounting Face
Figure 2-7. Three Main Bearings.
Some applications like generators, hydraulic pumps,
and others, require a separate bearing housing be
used to “connect” the load to the engine.
Gear Reducer - Where engine and driven speeds vary
greatly, or to permit the engine and equipment to
operate at a preferred RPM, a gear reducer may be
specified. Follow manufacturer’s recommendations for
installation and maintenance.
10
Section 3
Properly Installing the Engine
Properly Installing the Engine
In most applications, the provision of adequate power
is only part of the solution. It is careful attention to the
particular features of each application that will lead to
reliability, good engine performance, long engine life,
and customer satisfaction.
40%
Rejected to
Exhaust &
Radiation
The installation requirements addressed in this section
are to draw attention to the particular considerations
necessary in all applications.
30%
Rejected to
Cooling Air
Outlet
30%
Available for
Useful Work
Engine Location
Engine location is the key to proper installation, and it
must be considered in relationship to:
•
Unrestricted Cooling Air Flow (in and out)
•
Secure Mounting Provision
•
Availability of Combustion Air
•
Easy Serviceability
•
Good Exit of Exhaust Gases
•
Maintenance of Electrical System
•
Access to Fuel Supply
•
Access to Throttle and Choke
Each item is important to successful application of an
engine and should be considered when designing the
equipment and locating the engine.
Heat Distribution Chart.
It is equally important that there be an easy,
unrestricted exit of the heated air away from the
engine. Always remember: “easy access of engine
cooling air, In and Out.” This is critical.
Cutaway to
Show Fins
Heated
Air Out
Cooling
Fan
Ambient
Air Intake
Cooling Air
One of the most important factors effecting engine
performance, and engine life, is cooling air. Air-cooled
engines depend on a constant flow of cooling air to
remove the heat generated during combustion.
Approximately 70% of the heat value of fuel
consumed by an engine will be rejected to the
cooling air and to the exhaust. Without an adequate
flow of clean, unheated air into the engine, it will
overheat.
To emphasize the importance of this, a CH14 engine
will consume about 1 (U.S.) gallon (3.785 liters) of
gasoline an hour at 3200 RPM which can be seen in
the fuel consumption curve on page 4. The heat value
of one gallon of gasoline is about 120,500 BTU’s. Of
this, about 30% is rejected to the cooling air, another
40% is rejected along with the exhaust gases and to
radiation which leaves only about 30% of the input
available for useful work. The 70% rejected represents
84,350 BTU’s per hour.
Figure 3-1. Cooling Air Circulation.
Inlet Air Temperature - The temperature of the air into
the flywheel must be approximately the same as the
ambient air temperature. Installing the engine near
such equipment as hydraulic coolers, compressors, or
heaters, may cause the inlet air temperature to exceed
the ambient air temperature. See Figure 3-2.
11
Section 3
Properly Installing the Engine
•
Under no conditions should the inlet air temperature into the flywheel be more than 20°F (6.6°C) above the
ambient air temperature.
Heat Exchange
(From Other Equipment)*
Adds to Ambient
Air out
too Hot
Air in too Hot
Maximum Average
Temperature
cannot exceed
20°F (11°C)
*Located too Close to Engine
Figure 3-2. Avoid Heat Source near Engine.
Recirculation of Air - Heated air exiting from the
engine can be deflected by some obstruction back into
the flow of the cooling air, thereby raising its
temperature to unacceptable levels. Be sure there are
no pipes, walls, partitions, etc., in the path of air exiting
the engine. If contemplating using an oil cooler in the
cooling air intake stream, contact your Kohler Engine
representative.
Enclosures - If the engine must be located in a
building or enclosure, make certain that adequate air
intake and air outlet openings are provided. If
necessary, other means such as ducts or ventilating
fans will have to be used to provide adequate cooling
airflow.
Enclosure Causes
Recirculation
Too
Hot
No Outlet
Figure 3-3. Recirculated Air Adds to Heat.
12
Be sure room temperature remains cool enough so that
the inlet air to the engine fan is always below 130°F
(54.4°C). Ducting in small enclosures: the opening for
inlet air must be at least 1 1/2 times larger than the
blower housing inlet - and the opening for outlet air
must be at least 2 times larger than the size of the
blower housing outlet.
The size of those openings must be increased to
compensate for loss of air volume when louvers or
gratings are used.
When an application requires the engine be enclosed
or be mounted inside of equipment, it is advisable to
install a partition separating the inlet and exhaust air
vents as shown in Figure 3-4.
Section 3
Properly Installing the Engine
Enclosure
Easy In-Easy Out
Partition
Baffle
Large Opening
Allows Easy Outlet
of Heated Air
Large Opening
for Cooling Air
Figure 3-4. Partition Baffle Prevents Recirculation.
Mounting
When mounting an engine into an application,
consideration must also be given to torque reaction,
belt or chain side load (pull), end loading (thrust),
vehicle movement (rough terrain), and engine vibration
forces. Vibration frequency increases as engine speed
increases. This depends on the natural frequency of
the system (engine and unit).
Types of Mounting Systems - Solid or Flexible, with
the choice usually based upon the relationship
required between engine and machine.
1. Solid Mounting is effective, simple, and
inexpensive. It might contribute to operator
discomfort and to possible failure of mounting
points due to higher vibration levels.
Frame
Flexible
Mount
Figure 3-5. Typical Flexible or Isolator Mounting.
2. Flexible Mounting (or isolator mounts) enables
the supporting structure to be isolated from
engine vibration. Although more expensive, it is
effective and contributes to operator comfort. Be
aware of clearance problems caused by the
mounts and the movement (or “bounce”) of the
engine.
13
Section 3
Properly Installing the Engine
Resonance
At certain engine speeds, a condition of secondary
vibration, or resonance, may occur in machines. It is
caused when the vibration frequencies of the engine
and the natural frequencies of the equipment coincide
with each other and form a severe vibration. If not
corrected, resonance can cause fatigue failure of the
engine mounts, panel connectors, etc. This condition
should be corrected through speed alteration (if
possible), isolating the points of the resonant vibration,
or the use of isolator mounts.
Combustion Air/Air Intake
The air intake system (air cleaner) is one of the most
important aspects of engine installation, since it has a
direct effect on engine power output, fuel consumption,
exhaust emission, and engine life.
Dirt induced through improperly installed, poorly
serviced, or inadequate air cleaner elements wear out
more engines than does long hours of operation.
Controlling the combustion air through shielding or
ducting is desirable. Contact your Kohler Engine
representative regarding air cleaners, remote pick-up,
or heavy-duty air cleaner availability and use. The
various types are shown and listed in the Kohler
Engine Accessories Catalog.
17
1
2
14
16
13
12
*Liquid-Cooled Engines Only (LH version shown)
Figure 3-6. Some Service Points on Typical Engine.
14
If the location of the engine makes servicing difficult,
the required services may be neglected or may not be
performed at all, resulting in early failure of the engine.
When planning the installation, promote good service
by providing easy access to all service and
maintenance points.
Checklist
Here is a checklist to follow to make sure the engine is
easy to service.
•
Can the oil be checked, filled, and drained easily?
•
Are carburetor and governor adjustments
accessible?
•
Can the air and oil filter elements be changed
without difficulty?
•
Can the spark plug(s) be changed easily?
•
Is the cooling air intake screen easily accessible
for cleaning?
•
Can the starter be serviced or replaced without
removing the engine?
If you follow this checklist, your equipment will be easy
to service, and your customer will benefit from less
downtime and lower labor charges.
15
18
Service Access
1.
2.
3
3.
4
4.
5
5.
6
6.
7.
8.
7
9.
10.
8
11.
12.
13.
9
14.
15.
16.
10
17.
11
18.
Oil Level Dipstick
Air Cleaner Cover
Carburetor (under cover)
Governor
Oil Fill Cap (on either side)
#2 Valve Cover
#2 Exhaust Port
Spark Plug #2 Side
Oil Filter
Rectifier-Regulator
Oil Drain (starter side)
Oil Drain (oil filter side)
Starting Motor and Solenoid
Spark Plug #1 Side
#1 Valve Cover
Coolant Bottle*
Radiator*
Radiator Drain Plug*
Section 3
Properly Installing the Engine
Exhaust System
The exhaust system must channel hot exhaust gases
out of and away from the engine. The exhaust must be
directed away from the source of cooling air where it
cannot be recirculated and add to the temperature of
incoming air. The pipes and muffler must be located
where they will not restrict airflow.
Back Pressure: The exhaust system produces an
ever-present resistance to the flow of exhaust gases
called back pressure. If this pressure exceeds 40
inches (less for CS engines) of water, as read on a
water manometer, a significant loss of power will
result. EPA regulations require Kohler approval of all
non-factory exhaust systems.
Excessive back pressure can be caused by using an
unapproved muffler, exhaust piping too small in
diameter, too long, or with too many bends. Refer to
the Kohler Engine Accessories Catalog for approved
exhaust system components including all types of
mufflers, fittings, guards, shields, and spark arrestor
equipment.
Spark Arrestor: Check local, state, or federal laws to
determine if a spark arrestor is required, particularly if
the equipment is to be operated on state or federal
lands.
Heavy Mufflers: Adequate testing of heavy mufflers
should be done to make sure they are properly braced
and supported to withstand engine and/or load
vibrations.
Electric Start Systems
Electric start engines have a 12 volt starting circuit and
a battery charging system. Regulated charging circuits
with 15, 20, and 25 amp capacity are available (CS Pro
engines have 7, 10, and 18 amp systems). In addition,
unregulated charging circuits are available with lower
battery charging amperage and separate AC output for
lighting or accessories.
Battery Requirements: A 12 volt battery with a
minimum current rating of 250 cold cranking amps
(cca) should be sufficient for cranking most single
cylinder engine models. 400 cca is generally
recommended for twin cylinder models. The actual cca
requirement depends on engine size, application, and
starting temperatures.
Battery Cables: Use #4 or #6 gauge wire, from the
battery positive terminal to the starter switch or starter
solenoid, and from the negative terminal to ground.
Make certain that the remainder of the circuit from the
negative terminal to the engine block is electrically
equivalent. Ideally, the negative ground cable will be
connected directly from battery negative to the engine
block. Refer to chart below for SAE size and length
recommendations. Always use the shortest length of
wire possible.
SAE
Cable Size
Max. Length
6 Gauge
60.0 in. (152.4 cm)
4 Gauge
86.0 in. (218.4 cm)
2 Gauge
144.0 in. (365.7 cm)
Parasitic Starting Loads: This refers to any load that
is not disconnected from an engine while it is being
started. Normally a Kohler engine in good winterized
condition with fully charged battery will start at
temperatures down to minus 20°F (-29°C) without
any parasitic load. Parasitic loads such as hydraulic
pumps and hydrostatic drives can prevent starting at
lower temperatures. Starters can overheat and be
destroyed trying to crank cold equipment with
excessive parasitic loads. A parasitic load disconnect
should be considered during the design of the
application.
Ignition Systems
The Command, OHC/Triad, and Kohler Aegis™ twins,
and the Courage Series and CV/CH16 single cylinder
engines are equipped with capacitive discharge (CD)
ignition systems. The solid state system used on the
other Command engines is the inductive type. On
inductive types, timing is controlled by the module
position, so the firing point remains constant. See
Figure 3-7. The capacitive discharge systems can
have either fixed or variable ignition timing, depending
on engine model and customer requirements. See
Figure 3-8.
As temperatures decrease, cranking requirements
increase, but battery cranking capacity shrinks. Refer
to the Battery Capacity/Temperature Chart on page 26
to see the effects of declining temperatures on a
battery.
15
Section 3
Properly Installing the Engine
High Tension
Lead (C)
Ignition
Module
Spark Plug
Air Gap
Kill Terminal
Magnet
Laminations
Flywheel
Ignition
Kill Switch or
Module
Off Position
of Keyswitch
Figure 3-7. Fixed Timing Type Electronic Ignition System Schematic.
Operation: The CD ignition system functions much the
same as the inductive systems, with one exception. In
an inductive system, the voltage generated is fed
directly from primary to secondary to the spark plug.
The voltage cannot be held or stored, and the spark
timing doesn’t vary. In a CD system, the primary voltage
is used to charge a capacitor, where it is stored until it
receives a signal to release the charge to the
secondary and the spark plug. Although not done, the
charge could theoretically be held up to a full revolution.
The spark timing can also be varied through control of
the release signal to the capacitor. On some models, a
microprocessor is used to automatically adjust the
spark timing to the speed of the engine, to provide the
best possible combination of power and fuel efficiency.
Do not connect 12 volts directly to the ignition modules,
as this could burn the modules out. Excessive load on
the ground/kill circuit (some types of safety switches,
semiconductor circuits, etc.) can affect the performance
of CD ignition systems. Contact your Kohler Engine
representative to discuss.
Eyelet Terminal for Ignition
Key Switch (or Starter Post)
Oil Pressure
Safety
Red
Diodes
Ignition Module
Green
Red
White
B+ and
Carburetor
Solenoid
Input
Ignition
Modules
Spark
Plugs
Oil Pressure
Safety Input
Violet
B+
RectifierRegulator
For Customer Connected Tractor Applications
Figure 3-8. Electronic CD Ignition System Schematic.
16
Carburetor
Solenoid
White
Flywheel/Stator
Section 3
Properly Installing the Engine
Solenoid
Solenoid Shift Starter
Bendix Starter
Oil Sentry
Battery
Blue
Kill Accessories
A
Red
GND
Fuel Shut-off
Solenoid
Optional
Oil Sentry™
Indicator
Light
B+
Spark Plug
AC
Ignition Module
Key switch
AC
RectifierRegulator
Optional Oil Sentry™
Shutdown Switch
Spark Advance Module
Yellow
M
Violet
Red
Ground to Kill-White
Brown
Optional Ammeter
Green
Optional Fuse
Blue
Red
Yellow
Green
White
Red
Flywheel Stator
Figure 3-9. 15 amp Stator and Rectifier-Regulator.
Safety Advisory: Kohler Co. offers low-oil and high-temperature switches, which can be used to shut the engine
down or trigger a warning signal. Do not use the shutdown feature on mobile applications; use a light or audible
warning instead. See Figure 3-9.
Fuel Systems
Fuel Line
Fuel Line
Fuel Tank (Equipment
or Remote Mounted)
Fuel
In-Line
Pump
Fuel Filter
Vented Fuel
Tank Cap
Fuel Line
Fuel Pickup
Tube with Screen
Figure 3-10. Components of a Typical Fuel System.
17
Section 3
Properly Installing the Engine
The fuel consumption curves published in sales
brochures for each engine can be used to determine
fuel storage requirements if other than an enginemounted fuel tank is to be used. The brochure also
specifies whether the engine is equipped with a fuel
pump. Components of a typical fuel system with fuel
pump and remote tank are shown in Figure 3-10. A
gallon of gasoline (U.S. standard) weighs about 6.1
pounds and produces about 120,500 BTU’s of heat.
NOTE: A fuel shut-off valve is recommended on all
systems to stop fuel flow during periods of
non-use or when transporting or servicing the
equipment. A fuel filter should also be
installed ahead of the fuel pump on fuel lift
systems or ahead of the carburetor on gravity
feed systems. Contact your Kohler Engine
representative for fuel filter micron rating
requirements.
Gravity Feed System: This system is generally used
on engines without fuel pumps. The bottom of the fuel
tank should be at least 3 in. (76.2 mm) above the fuel
inlet on the carburetor to ensure sufficient pressure to
open the inlet valve on the carburetor.
NOTE: If the tank is located more than 20 in.
(50.8 cm) above the fuel inlet, the pressure
could exceed the pressure of the float valve,
causing the carburetor to overflow. Install a
fuel flow regulator to prevent this. See Figure
3-11.
Gravity Feed Limits:
3 in. (76.2 mm) Minimum
20 in. (50.8 mm) Maximum
In-Line
Fuel
Filter
Remote
Tank
Carburetor
Fuel Inlet
Fuel Shutdown
Solenoid
Figure 3-11. Gravity Feed System With Remote
Tank.
18
Fuel Lift System: If the engine is equipped with a
mechanical fuel pump, the tank can be located below
the carburetor but not more than 3 ft (91.44 cm) below
the fuel pump. An electric fuel pump is available to
provide maximum suction up to 10 ft (3.048 m). Refer
to the Kohler Engine Accessories Catalog. If a vacuum
pulse pump is used, the maximum lift is 18 in.
(45.7 cm). Operation of vacuum pulse pumps is
affected by altitude; diminished performance will be
experienced at higher elevations.
3 ft (91.44 cm) (Maximum) Lift*
Remote Tank
Fuel
Pump Inlet
*With Mechanical Pump
Figure 3-12. Fuel Lift Limits with a Mechanical
Fuel Pump.
Fuel Lines: Keep fuel lines as short as possible
[maximum 10 ft (3.048 m)], avoid kinks and loops in
the lines. Route fuel lines along the bottom of the
engine compartment, away from all high temperature
components. The fuel lines must be a minimum of
1/4 in. (6.35 mm) inside diameter and be of high
quality material meeting SAE specifications for fuel
lines. An in-line fuel filter is recommended, especially
in extremely dusty and dirty applications.
Avoid “Vapor Lock”: Vapor lock is simply boiling fuel.
As fuel gets hot it forms a vapor in the fuel lines,
causing the engine to stall. Restarting is impossible
until the fuel in the line cools to liquid state again.
Route fuel lines away from areas of extreme heat and
keep temperatures in the engine compartment from
becoming too hot.
Fuel Recommendations
Gasoline
For best results, use only clean, fresh, unleaded
gasoline with a pump sticker octane rating of 87 or
higher. In countries using the Research method, it
should be 90 octane minimum.
Section 3
Properly Installing the Engine
Unleaded gasoline is recommended, as it leaves less
combustion chamber deposits. Leaded gasoline may
be used in areas where unleaded is not available and
exhaust emissions are not regulated. Be aware
however, that the cylinder head will require more
frequent service due to extra deposits from leaded
fuel.
Gasoline/Alcohol blends
Gasohol (up to 10% ethyl alcohol, 90% unleaded
gasoline by volume) is approved as a fuel for Kohler
engines. Other concentrations are not approved.
Gasoline/Ether blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blends (up to a maximum of 15% MTBE by
volume) are approved as a fuel for Kohler Engines.
Other concentrations are not approved.
All Kohler engines meet applicable Emission
Control Regulations.
Alternate Fuels
Liquefied Petroleum Gas (LPG) and Natural Gas may
be used on some Kohler engines. Contact your Kohler
Engine representative for specifics on the use of these
fuels. To plan for a permanent installation (such as a
home standby generator) using utility-supplied
gaseous fuel, refer to the supply requirements in
Section 5, Technical Guidelines.
Engine Controls
Whenever convenient, consider using engine-mounted
throttle and choke controls. Automatic chokes,
solenoid operated chokes, and idle solenoids are
available on some engine models. With constant
speed applications, the throttle linkage allows the
engine to come up to full RPM almost immediately
after start-up. When remote controls are needed,
single or dual cable throttle/choke control systems are
offered. For specific details on actual hook-up of the
controls and adjustments procedures, refer to
TP-2445-A.
Governor Operation: Kohler engines are equipped
with a centrifugal mechanical governor to hold speed
constant under changing load conditions. The governor
mechanism is mounted inside the crankcase and is
driven off the crankshaft or camshaft. Refer to Figure
3-13 for typical components as described in the
following explanation.
Throttle Linkage
Governor Arm
Cross Shaft
Tab
Carburetor
Throttle Lever
Flyweights
Governor Gear
Assembly
Regulating
Pin
Governor
Spring
High Speed Stop
Throttle Control
Figure 3-13. Typical Governor Components.
Centrifugal force acting on the rotating governor gear
assembly causes the flyweights to move outward as
speed increases. As the flyweights move outward they
force the regulating pin of the gear assembly to move
outward. The regulating pin contacts the tab on the
cross shaft, causing the shaft to rotate with changing
speed. One end of the cross shaft protrudes through
the side of the crankcase, and has a lever or arm
attached to the protruding end. A linkage connects one
end of the governor arm to the throttle lever in the
carburetor, so the rotational movement of the governor
shaft moves the throttle plate in the carburetor toward
the closed position. The governor spring is hooked
between the opposite end of the governor arm and the
throttle control lever.
When the engine is at rest and the throttle control is in
the “fast” position, the tension of the governor spring
holds the throttle valve open. When the engine is
started and comes up to speed (governor gear
assembly is rotating), the force applied by the
regulating pin against the cross shaft tends to close
the throttle valve. The governor spring tension and the
force applied by the regulating pin are in “equilibrium,”
holding the engine speed constant.
19
Section 3
Properly Installing the Engine
When a load is applied and the engine speed (and
governor speed) decreases, the governor spring
tension moves the governor arm to open the throttle
plate wider. This admits more fuel and restores engine
speed. This action takes place very rapidly, so a
reduction in speed is hardly noticed. As the speed
reaches the governed setting, the governor spring
tension and the force applied by the regulating pin will
again be in equilibrium. This maintains engine speed at
a relatively constant level.
Governed speed may be at a fixed point as on
constant speed applications, or variable as determined
by a throttle control lever.
Understanding how the governor functions should help
in connecting controls to the control plate and to
properly adjust the governed speeds. Other types of
governors are available including Electronic
Governing. Contact your Kohler Engine representative
for information on using or converting to this type of
system. Refer to TP-2445-A for connecting and
adjusting Throttle and Choke Controls on various
Kohler Engine Models.
20
Engine Speed Settings
The high and low idle speed settings on all Kohler
engines are set in our engine test cell after assembly.
Unless otherwise specified by an OEM customer,
standard Kohler RPM specifications are followed
(usually 1200 RPM idle, 3750 RPM max.).
These settings are made on a new, cold engine that is
run for less than eight minutes with no load. Engine
break-in and warm-up can be expected to alter the
initial factory settings, usually resulting in a speed
increase. Installation on a piece of equipment is also
likely to affect the settings, with the applied load
usually resulting in a speed decrease. Speed readings,
after installation, break-in, etc., can be expected to
deviate from the factory settings by ±150 RPM at high
idle and ± 200 RPM at low idle (optional governed idle
devices can reduce idle fluctuations on some models).
It is recommended that the OEM run a sufficient
number of test units to verify that the factory
specifications result in the desired speed in the final
product configuration. Contact your Kohler Engine
representative if further information is required.
Section 4
Testing the Installation
Testing the Installation
Engine application testing can range from simple field
checks to complex setups requiring expensive and
sophisticated monitoring devices. In general, the types
of testing you do will depend upon your equipment.
Heat Tests
There is at least one test that is critical: The Heat
Test!
It is most important that you gather temperature test
data at several key areas. Heat tests are done by
installing thermocouples at the following points.
a. Spark plug temperatures are checked by a special
thermocouple installed under the spark plug.
b. Oil sump temperatures are checked with a
thermocouple that fits on the oil dipstick about
1/2 in. (12.7 mm) below the tip.
c. Air temperature into the cooling fan is checked by
fastening a thermocouple to the blower housing
with the junction in the incoming air stream
checks. The junction (or welded thermocouple tip)
should be 1/4 to 1/2 in. (6.35 to 12.7 mm), from
the grass screen. It is best to check at three or
four locations around the inlet and average the
temperatures (3,6,9, and 12 o’clock positions).
d. Air temperature into the carburetor inlet is checked
by clamping the thermocouple wire under the air
cleaner element, with the junction in the air stream
above the choke plate. Set engine at rated, noload, speed. Attach a tachometer to monitor
engine speed.
Ideally, your engine installation should be tested in a
controlled environment, kept at 110°F (43.3°C).
Variable speed applications should be loaded so that
the engine is tested with wide-open throttle (WOT). The
engine must be loaded until the speed does not
increase when the governor lever is pushed. Constant
speed applications should be loaded so that the engine
is tested WOT at the specified governed constant
speed. These can be simulated or can be done under
actual working conditions. The machine must be run
under these conditions until temperatures have
stabilized and are no longer increasing. (This usually
takes about 1 hour of steady operation.)
Sometimes it is impossible to test the equipment in the
110°F (43.3°C) environment, so a second set of engine
temperature values are listed for a 75°F (24°C)
environment. Note that the permitted guidelines are
reduced, since the engine will operate at lower
temperatures when tested at a lower ambient
temperature. Consult your Kohler Engine representative
for a review of the observed temperatures.
Key Area
110°F (43°C)
75°F (24°C)
A Spark plug
B Head bolt
C Oil sump
D Air into cooling fan
E Air into carburetor inlet
550° (288°)
500° (260°)
325° (163°)
130° (54°)
175° (79°)
500° (260°)
470° (243°)
275° (135°)
95° (35°)
125° (52°)
After the temperatures have become stabilized and are
recorded, stop the engine. Let the machine sit for 10 to
15 minutes and then try to start it again. This will give
you an indication whether your application is
susceptible to vapor lock.
Starting Tests
Cold Starting: A Kohler engine in good condition, with
no parasitic load, should start well at -20°F (-6.6°C).
(Parasitic load refers to any load that is not
disconnected during starting, such as a hydraulic
pump or hydrostatic transmission.)
To test for cold starting ability in your application, the
following test equipment must be prepared:
A 12 volt battery with a minimum current rating of 250
cold cranking amps (cca) for single cylinder models, or
400 cca for twins.
• Voltmeter connected between the positive
terminal on the starter and the engine block.
• Ammeter connected to measure the current in
the positive cable between the battery and
starter, capable of measuring up to 300 amps.
• Tachometer capable of reading RPM in the 100 to
500 range.
• Thermometer or thermocouple to measure
ambient temperature.
The temperatures reached must not exceed those
listed in the following table in the 110°F (43.3°C)
ambient test environment.
21
Section 4
Testing the Installation
Ideally, the test should be performed in a special “cold
room” where low temperatures can be developed and
controlled by refrigeration. Since cold room testing is
an elaborate and expensive procedure, you may not be
able to run such tests. Instead, you can leave the
machine for 12 hours at the lowest temperature at
which you expect it to be used, then test it for starting,
using the test equipment noted on page 21.
Exhaust System Tests
If the muffler is not supplied by Kohler, EPA requires
that the OEM certify that back pressure does not
exceed 40" water at 3600 RPM at wide-open throttle
(WOT).
1. Weld the pipe coupling (1/8" NPTF) to the
exhaust pipe as shown in the inset of Figure 4-1.
The spark plug leads should be disconnected and
grounded while observing starter voltage, current, and
engine RPM. The starter should be engaged and
readings taken of voltage, RPM and current (ignore the
initial surge). Note the ambient temperature.
Using the line showing the temperature closest to your
observed ambient temperature, compare your test
readings with the minimums and maximums noted.
Consult your Kohler Engine representative for a review
of the reading observed.
Ambient
Temp.
Minimum
Voltage
Minimum
RPM
Typical
Current
0°F (-18°C)
20°F (-6°C)
50°F (10°C)
70°F (21°C)
8.5
9.0
9.5
10.0
250
300
350
350
150 Amp
120 Amp
80 Amp
60 Amp
If voltage is below the minimum, there are several
possible causes:
1. Battery is discharged or is too small (insufficient
capacity).
2. Cables are too long or too small.
3. Poor connections at starter, battery (+ & -), switch,
or in ground circuit.
4. Inadequate ground circuit between (-) terminal on
battery and engine block.
5. Too much parasitic load.
If the RPM is below the minimums and battery voltage
is OK, possible causes are:
1. Too much parasitic load.
2" Max.
1/4" Dia. Hole
Figure 4-1. Measuring Exhaust Back Pressure.
2. Drill a 1/4" diameter hole through the exhaust pipe
wall in the center of the coupling.
3. Attach the copper tube assembly (SPX Part No.
KO1011C*) to the coupling. Position the loop
away from the exhaust system, or in the cooling
air stream if possible. See Figure 4-1.
4. Connect gauge (SPX Part No. KO3223*) or
manometer (SPX Part No. KO1005) to the copper
tube.
*Part available from SPX Corp. OTC.
Call 1-800-533-0492.
5. Move the on/off valve to the off position if using
manometer. Start the engine and bring it to
operating speed (3200-3600 RPM). Apply load
until wide-open throttle (WOT) is reached.
6. Open the on/off valve (manometer only), and
measure the back pressure. Check your reading
against the table below.
2. Defective starter.
Note that when RPM is below minimum, the current is
likely above maximum amperage, which will quickly
lead to starter failure due to overheating.
22
90º
Cylinder Block
Engine Series
Max. Allowable Exhaust
Back Pressure at WOT
Courage,Command,Aegis™
40" H2O
OHC/Triad
45" H2O
Section 4
Testing the Installation
7. Close the on/off valve of the manometer before
stopping the engine.
Vibration Testing
Vibration testing also requires sophisticated
equipment. Vibration however, may be a more
subjective matter than an objective one. Operate the
equipment. Do you find the vibration unpleasant,
distracting, or dangerous? The level at which vibration
becomes a problem will vary from operator to operator,
but you can make a fair estimate of the vibration levels
simply by operating the equipment yourself.
What we have done in this section is to give you a
general idea of the minimum testing necessary to
ensure that your equipment and our engine are a good
match.
Is That All There Is?
The engine performance check outlined in this guide is
quite simple, and for most applications, it should give
you an adequate basis for selecting the right engine,
for installing it properly, and for testing the application.
At Kohler, we are constantly testing our engines to
improve their suitability for your needs.
Our testing facility, for instance, has rooms in which
temperatures may be maintained at any desired level.
We test engines over a wide range, from extremely hot
to very cold. Highly sensitive monitoring devices
provide accurate readings of the various temperatures
in critical engine areas. We can load engines or
engine-powered equipment to any degree needed for
accurate testing. Our quiet room enables us to
measure sound levels without the interference of
ambient noise. We have accelerometers to measure
engine vibration, equipment to measure fuel
consumption, equipment to test mechanisms, and
equipment to do other tests that enable us to
manufacture the best possible engines for our
customers.
If you have problems in your testing program, let your
Kohler Engine representative know about them. At
Kohler, we’re as interested as you are in seeing that
our engines are properly matched to your equipment.
Special Considerations
Angle of Operation must be a consideration, though
each engine has its own limitations in each direction.
As a rule of thumb, a 25° limit in any direction should
be followed.
Application Review - It is a link in the chain toward
complete satisfaction. Match the engine to the job, so
the engine can do the job it was designed to do.
Account Information Record
Prepare a Kohler Co. Account Information Record
(AIR) form for review by our engineers. This is
especially important where unusual power drives are
used. (For instance, a very small pulley located far
from the engine would be an unusual power drive.)
Avoid adding special mounting brackets or
attachments to the engine, as they could introduce
high-stress points, which might lead to subsequent
bracket or fastener failure.
By carefully considering all of these points when you
design your equipment, you can avoid many
troublesome areas that may show up in testing or in
the field. By preventing problems at the design stage,
you save time, money, future service problems, and
frustration.
Design Check Points
• Keep cooling air to the fan no greater than 20°F
(11°C) above ambient temperature and no more
than 130°F (54°C).
• Make sure all service points are easily
accessible.
• The muffler used should not create more back
pressure than the maximum amounts shown in
the table on page 22.
• Keep fuel lines as straight as possible, with no
kinks or loops.
• Whenever possible, avoid parasitic loads.
• Prepare Account Information Records forms for
review by Kohler Co.
• Air cleaner systems are governed by EPA
regulation, non-standard air cleaners are not
recommended. If a non-standard system is
used, including any changes or modifications to
a Kohler-supplied system, laboratory
confirmation of EPA compliance will be required.
23
Section 5
Technical Guidelines
Technical Guidelines
This section contains some additional information,
which may be useful in calculating engine
requirements for some specific applications and/or for
basic engine educational purposes.
Horsepower Definition
One horsepower is the timed rate of force required to
lift a weight of 33,000 pounds one vertical foot in one
minute. The formula is 1 HP=33,000 ft. lb. per minute
or 550 ft. lb. per second.
Power Conversion Table
1 Horsepower - hour = 2544 BTU
1 Horsepower - hour = 0.746 Kilowatt-hour
1 Horsepower = 746 Watts (0.748 Kilowatt)
1 Kilowatt = 1.34 Horsepower
1 Kilowatt = 1000 Watts
Engine HP Developed (Approximate)
Gasoline Fuel = 12 HP hours per U.S. gallon
Liquid Propane (LPG) = 10 HP hours per U.S. gallon
Power Calculations (Some common applications)
Use the following formulas below to calculate rough
requirements for some typical engine applications.
Contact the equipment manufacturers for specific
details.
PUMP, Water
GPM* x Total Dynamic Head (in feet)
HP =
3960 x Efficiency (50% factor if unknown)
HP =
GPM* x Pressure (psi)
1714 x Efficiency (50% factor if unknown)
PUMP, Trash
GPM* x Head x Specific Gravity
HP =
3960 x Efficiency (40% factor if unknown)
HP =
GPM* x Pressure (psi) x Specific Gravity
1714 x Efficiency (40% factor if unknown)
PUMP, Hydraulic
GPM* x Pressure (psi)
HP =
1714 x Efficiency (80% factor if unknown)
FLOW RATE at Pump
RPM x Pump Displ. (Cu. in./Rev.)
Flow (GPM) =
231
*GPM = Gallons Per Minute
24
Constants Used In Connection With
Pumping Liquids
acre foot
atmosphere
cubic foot
cubic foot per second
cubic foot of water
foot head of water
foot head of water
inch of mercury
inch of mercury
U.S. gallon of water
U.S. gallon
pound per square inch
pound per square inch
Imperial gallon
Welder
HP =
= 325,900 U.S. gallons
= 34 feet head of water
= 7.48 U.S. gallons
= 448.8 gallons per minute
= 62.4 pounds
= 0.4335 pounds per sq. in.
= 0.89 inches of mercury
= 1.133 feet head of water
= 0.4912 pounds per sq. in.
= 8.34 pounds at 60°F
= 231 cubic inches
= 2.31 feet head of water
= 2.03 inches of mercury
= 1.2 U.S. gallons
amps x volts
746 x Efficiency (70% factor if unknown)
Generators
HP =
Kilowatts x 1.34
Efficiency (70% factor if unknown)
NOTE: 2 HP per kW required at 70% efficiency.
Compressor, air (piston type)
• Allow 0.25 brake HP for each cubic foot of free
air drawing against a working pressure of 75 to
100 psi.
BHP = 0.25 x cubic foot minute.
• When compressor and engine are direct
connected and operated at same speed, the
cubic inch displacement of compressor
multiplied by 1.3 will give the displacement of the
engine required.
Section 5
Technical Guidelines
Belt Drives
Pulley Selection: Using larger pulleys allows reducing
belt tension and bearing loading resulting in increased
bearing, belt and pulley life. When idler pulleys are
used for tensioning and take up, they should be spring
loaded to provide nearly constant tension. When an
idler is used for clutching, it should be located close to
the drive pulley. Idler pulleys should be located on the
belt slack side or belt strand going away from the drive
pulley. The belt manufacturer should be contacted for
specifics regarding pulleys. Generally, the outer
diameter of pulleys used with A-type belts should be no
less than 3.5 in. (90 mm) while the pulley O.D.
minimum is 4 in. (101.6 mm) with B-style belts. There
are exceptions to these recommendations, which
should be reviewed with belt manufacturers. The
average O.D. of drive pulleys used on Kohler engines is
4 in. (101.6 mm).
The following is provided as a guide to selecting the
best belt cross-section and pulleys to use after the
basic belt drive configurations has been determined.
Contact belt manufacturers for assistance in finalizing
the drive and selecting the best belt construction to
use for your particular application. Factors such as
shock loading, alignment, heat, dirt, engagement and
disengagement must be considered.
To use the chart, the speed of the faster shaft and
peak design horsepower must be known. If the
intersecting points for your application fall above and/
or to the left of the cross sectional line, the section
letter indicated should provide good service life. If,
however, it falls below and/or to the right of the line, go
to the next letter.
Belt Speed: Is calculated as the circumference of a
pulley times its revolutions per minute. For a 6 in.
diameter (0.5 ft), the circumference is figured as
3.1416 x .5 = 1.57. If the belt speed in this example is
500 RPM, multiply 500 x 1.57 which equals 785 feet
per minute.
Cross Section: Use the chart below to make the initial
selection of the best belt cross section – final selection
will depend on pulleys used and drive geometry.
5000
.50"
4000
3450
3000
A
RPM of Faster Shaft
2500
2000
1750
1500
.66"
B
A
1160
1000
870
C
400
C
300
D
150
2
3
4
5
6 7 8 9 10
15
20
.53"
1.25"
200
1
.41"
.88"
B
690
600
575
500
100
.31"
30
D
.75"
40 50
Design Horsepower
25
Section 5
Technical Guidelines
Belt Length: Belt length is usually determined by
placement of driven load. Belt length is considered as
the distance between the center of the drive (driver)
and driven pulleys. One formula for calculating length
is as follows:
BL = 1.57 (D + d) + (TCD x 2)
In this:
BL = Belt Length
D = Diameter of Driver Pulley
d = Diameter of Driven Pulley
TCD = Tentative Center Distance
1.57 = Constant
Battery - Supplemental Information
Battery capacity or output shrinks as the temperature
decreases, as shown in the chart below. At about 80°F,
a fully charged battery in good condition should be at
100% capacity. At 20°F (-6.7°C) the capacity shrinks to
about 30%. Unfortunately, the cranking requirements
steadily increase as temperatures decrease. Make
sure the cold cranking amperage (cca) rating of the
battery used is at least 250 cca for single cylinder
engines or 400 cca for twins at 0°F (-17.8°C).
ºF
Belt Tension: Tension is usually not critical, however
too much or too little tension could shorten belt and
bearing life. New belts usually stretch somewhat
during initial run-in and may slip. Check tension of a
new belt after the initial operation. Correct tension is
the lowest tension at which the belt will not slip under
highest load condition. Generally, the belt should
deflect about 1/64 in. (0.396 mm) for each inch of span
length. The formula for determining deflections is:
Deflection = 0.016 inch x Length of Span (center to
center)
For example, if the length of a span is 18 inches:
Deflection = 0.016 x 18 = 0.288 in. or about 9/32 in.
(7.14 mm)
To check tension, place a straight edge across the
span and push the belt down midway between the
pulleys and measure the deflection. Adjust tension as
needed.
26
70º
85%
60º
Degrees Fahrenheit
BL = 1.57 (6 + 4) + (18 x 2)
or
BL = 1.57 x 10 + 36
or
BL = 15.7 + 36 = 51.7
100%
80º
As an example, if the diameter of the Driver pulley is
6 in., the driven pulley is 4 in., and the centers are
18 in. apart, this would calculate as follows:
50º
40º
65%
30º
20º
10º
45%
0º
-10º
30%
-20º
-30º
10
20 30 40 50 60 70 80 90
Percentage of Capacity
Battery Capacity/Temperature Chart.
100
Section 5
Technical Guidelines
Gaseous Fuel Installation - Supplemental Information
Gaseous fuels have less heat energy than gasoline. To utilize supply from a local utility, it is important to confirm
that the supply will be adequate to meet the demand of the engine. Consult the gas utility company for a home fuel
demand analysis prior to installation. A larger gas meter and/or separate supply line may be required. Fuel supplied
to the engine must meet the specifications below for expected performance and durability. Failure to do so may
result in hard starting, low power, and/or reduced engine life.
Fuel energy content can vary by geographic region. Production of full rated power requires 1000 BTU/cu. ft. for
natural gas and 2500 BTU/cu. ft. for propane.
The engine is designed to operate between 5-15 water-column-inches fuel pressure (measured at the secondary fuel
regulator with engine under full load), and can demand up to 200 cu. ft./hr. of fuel flow. Verify that the fuel line
diameter is properly sized, based upon the distance from the gas meter.
Gas Pipe Length from Meter (ft.)
Minimum Gas Pipe I.D. (in.)
25
3/4
50
1
100
1
150
1 1/4
200
1 1/4
Metric Conversion Factors
Units of Measure
Force
Pound-force (lbf) x 4.448 = Newton (N)
Length
Inches x 25.4 = Millimeter (mm)
Mass
Pound (lb) x 453.592 = Grams (g)
Ounce ¸ 28.350 = Grams (g)
Oil Consumption
Pound/hour (lb/h) x 453.592 = Grams/hour (g/h)
Fluid ounce/hour (fl·oz/h) x 29.574 = Milliliter/hour
(mL/h)
Power Output
Horsepower (HP) x 0.746 = Kilowatt (kW)
Pressure & Stress
Inch of Water (in/H2O) x 0.249 = Kilopascal (kPa)
Inch of Mercury (in/Hg) x 3.377 = kilopascal (kPa)
Pound-force/square inch (lbf/in2) (psi) x 6.895 =
Kilopascal (kPa)
Pound-force/square inch (lbf/in2) (psi) x 0.0069 =
Megapascal (Mpa)
Specific Fuel & Oil Consumption
Pound/Horsepower-hour (lb/hp·h) x 608.277 = Gram/
Kilowatt-hour (g/kW·h)
Temperature
Degree Fahrenheit 5 x (°F-32) = Deg. Celsius (°C)
9
Torque
Pound-force-inch (lbf·in) x 0.113 = Newton-meter (N·m)
Pound-force-foot (lbf·ft) x 1.356 = Newton-meter (N·m)
Volume (Capacity)
Cubic inch (in3) x 16.387 = Milliliter (mL)
Cubic centimeter (cm3)
Fluid ounce (fl·oz) x 29.574 = Milliliter (mL)
Cubic centimeter (cm3)
Pint (pt) x 0.473 = Liter (L)
Quart (qt) x 0.946 = Liter (L)
Gallon (gal) x 3.785 = Liter (L)
Cubic foot (ft3) x 0.0283 = Cubic meter (m3)
Cubic foot (ft3) x 28.317 = Liter (L)
Volume Flow
Cubic foot/minute (ft3/min) x 28.317 = Liter/minute
(L/min)
Cubic foot/minute (ft3/min) x 0.0283 = Cubic meter/
minute (m3/min)
Miscellaneous
Diameter of Circle: Circumference x 0.31831
Circumference of Circle: Diameter x 3.1416
27
FOR SALES AND SERVICE INFORMATION
IN U.S. AND CANADA, CALL
1-800-544-2444
www.kohlerengines.com
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
FORM NO.: TP-2132-D
ISSUED:
8/83
REVISED: 3/04
MAILED:
LITHO IN U.S.A.
WARRANTY
POLICY AND PROCEDURE
Contents
Section 1 – Introduction
A. The Warranty Decision ............................................................................................................................................. 3
B. Pre-Sale Disclosure Requirement ............................................................................................................................ 3
C. Warranty Responsibility Begins Before Delivery ...................................................................................................... 3
Section 2 – Limited Warranty Statements
A. Kohler Aegis Warranty Statement ............................................................................................................................ 4
B. Courage SV470-610, SV710-740 Warranty Statement ............................................................................................ 4
C. Courage PRO SV810-840 Warranty Statement .................................................................................................. 5
D. COMMAND PRO/Command/Magnum/OHC Warranty Statement ........................................................................... 5
E. K-Series Warranty Statement ................................................................................................................................... 6
F. Service Parts Warranty ............................................................................................................................................ 6
G. Kohler Co. Federal and California Emission Control Systems Warranty Statement ............................................. 7-8
Section 3 – Warranty Procedures
A. Service Information Record (SIR) ............................................................................................................................ 9
B. Warranty Repair Authorization ............................................................................................................................... 10
C. Manufacturing Defects Covered ............................................................................................................................. 10
D. Major Warranty Repair ........................................................................................................................................... 10
E. Carburetor Warranty Replacement ........................................................................................................................ 10
F. Retaining Failed Parts ............................................................................................................................................ 10
G. Return of Failed Parts ....................................................................................................................................... 10-11
H. Disputed, Questionable, Unusual Warranty, or Policy Adjustments ....................................................................... 11
I. Engines Manufactured Over 3 Years Ago ......................................................................................................... 11-12
Section 4 – Warranty Service Parts
A. Policy ...................................................................................................................................................................... 12
B. Defective Service Parts (New Inventory) ............................................................................................................... 12
C. Defective Service Parts (Installed) ......................................................................................................................... 12
D. Defective Service Parts (Installed During Engine Warranty Period) ...................................................................... 12
E. Warranty Options and Accessories ........................................................................................................................ 12
1. Options (Factory Installed) ............................................................................................................................. 12
2. Accessories (Field Installed) .......................................................................................................................... 12
Section 5 – Warranty Exclusion
A. Non-Reimburseable Items ...................................................................................................................................... 13
Section 6 – Claims Procedure
A. Responsibility for Submitting Proper and Completed Warranty Claim Forms ........................................................ 13
B. Warranty Claim Report Forms ................................................................................................................................ 13
C. Warranty Claim Instructions .............................................................................................................................. 13-15
Section 7 – Reimbursement Procedures
A. Policy ...................................................................................................................................................................... 15
B. Reimbursement Calculation Details .................................................................................................................. 15-16
1. U.S.A. & Canada, Non-Expert ................................................................................................................... 15-16
2. U.S.A. & Canada, Expert ................................................................................................................................ 16
3. International, Non-Expert ............................................................................................................................... 16
4. International, Expert ....................................................................................................................................... 16
C. Freight Cost U.S.A. & Canada (FOB and Truck) .................................................................................................... 16
Section 8 – Engine Inspection Data Record
A. Engine Inspection Data Record Instructions .......................................................................................................... 16
B. Engine Inspection Data Record ........................................................................................................................ 17-19
Section 9 – Flat Rate Schedules
A. Command Pro CS Series Flat Rate Schedule ....................................................................................................... 20
B. Courage XT-Series, Courage Single, and Command Single Flat Rate Schedule .................................................. 21
C. Command Twin and Command PRO Twin Flat Rate Schedule ........................................................................ 22-23
D. Courage Twin, Courage PRO Twin, and Aegis Flat Rate Schedule .................................................................. 24-25
E. OHC Flat Rate Schedule ........................................................................................................................................ 26
F. Magnum Flat Rate Schedule .................................................................................................................................. 27
G. K-Series Flat Rate Schedule .................................................................................................................................. 28
Policy Adjustment Explanation Form ............................................................................................................................. 29
Carburetor Replacement Evaluation Form .................................................................................................................... 30
2
Section 1 – Introduction
A. The Warranty Decision
Warranty decisions must be based on careful
examination of the facts and circumstances surrounding
the warranty request. The warranty covers defects in
material or workmanship, so you must try to decide if the
failure resulted from a manufacturing defect and is
eligible for warranty consideration. If you feel that a
decision will be difficult, or the customer is disputing your
decision, complete an Engine Inspection Data Record
(TP-2435), as shown on pages 17-19, and follow a
systematic analysis procedure.
1. Complete the Owner’s Information portion of the
Engine Inspection Data Record when the customer
brings the unit in for consideration.
2. Inspect the unit as delivered and complete the Air
Filter Assembly, Crankcase Oil, Engine Cooling
System, and Governor sections of the Engine
Inspection Data Record.
NOTE: Experience has shown that the information
gained from these sections frequently will
lead to the cause of the failure, and will
determine what corrective action must be
performed to prevent repeat failures.
3. Carefully disassemble the engine and check
components for any unusual markings or wear
patterns.
4. Take the necessary measurements and enter them
in the proper sections in the Engine Inspection Data
Record. Compare the measurements against
published specifications in Kohler service literature
to identify parts that may require rework or
replacement.
If there is a question whether the repair is covered by the
Kohler Limited Engine Warranty, contact your Kohler
Distributor to assist you in the analysis and warranty
decision.
If, after reviewing the matter with the Kohler Distributor
representative, a warranty decision still cannot be made,
have the representative follow the ‘‘chain of command’’
until a decision is reached. Remember, always keep the
customer advised as to what is being done, and why.
This will show the customer full consideration is being
extended and will demonstrate our mutual concern.
B. Pre-Sale Disclosure Requirement
One of the provisions of the Magnusson-Moss Consumer
Products Warranties Law is that a retail seller of
consumer products must make the text of the warranty
available for review by the prospective buyer prior to
sale. To help you comply with this law, the warranty
statements for each model series are printed at the back
of the owner’s manual for that series. All of the warranty
statements are included in Section 2 of this booklet.
C. Warranty Responsibility Begins Before Delivery
Each Kohler Service Account is responsible for
preventing new engines (and parts) from deteriorating in
storage, and also for preparing new engines for delivery.
Failure to adequately protect and store engines and parts
will result in unnecessary expense to the dealer, and will
inconvenience and annoy customers. Successful service
accounts have proven that the minimal investment
involved in preparing an engine prior to delivery
eliminates unnecessary service calls and results in
improved over-all profit. Before turning an engine over,
review the Owner’s Manual with the customer–stress the
importance of good maintenance and explain the
warranty.
If your analysis points to a deficiency in engine care or
maintenance, recommend to your customer the
preventive measures that must be performed to prevent
repeat failures.
3
Section 2 – Limited Warranty Statements
KOHLER Aegis® Warranty Statement
Limited 3 Year Kohler Aegis® Engine Warranty
Kohler Co. warrants to the original retail consumer that each new KOHLER AEGIS® engine sold by Kohler Co. will be free from manufacturing defects in
materials or workmanship in normal residential service for a period of three (3) years from date of purchase, provided it is operated and maintained in
accordance with Kohler Co.’s instructions and manuals.
Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044, or at a service
facility designated by us of such parts as inspection shall disclose to have been defective.
EXCLUSIONS:
Mufflers on engines used commercially (non-residential) are warranted for one (1) year from date of purchase, except catalytic mufflers, which are
warranted for two (2) years.
This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide reasonable and
necessary maintenance.
The following items are not covered by this warranty:
Engine accessories such as fuel tanks, clutches, transmissions, power-drive assemblies, and batteries, unless supplied or installed by Kohler Co. These
are subject to the warranties, if any, of their manufacturers.
KOHLER CO. AND/OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY
KIND, including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts.
IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE
EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other express warranty, nor is any one authorized to make any
on our behalf.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the
above limitation or exclusion may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state.
TO OBTAIN WARRANTY SERVICE:
Purchaser must bring the engine to an authorized Kohler service facility. To locate the nearest facility, visit our website, www.kohlerengines.com, and click
on SALES AND SERVICE to use the locator function, consult your Yellow Pages or telephone 1-800-544-2444.
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
KOHLER COURAGE® SV470-610, SV710-740 ENGINE LIMITED WARRANTY
Kohler Co. warrants to the original retail consumer that each new COURAGE® engine sold by Kohler Co. will be free from manufacturing defects in
materials or workmanship in normal residential homeowner service for a period of two (2) years from date of purchase, provided it is operated and
maintained in accordance with Kohler Co.’s instructions and manuals. If used commercially the COURAGE® engine is covered by a 90 day limited
warranty.
The warranty period begins on the date of purchase by the original retail consumer or commercial end user. “Residential homeowner service” means
residential use by a retail consumer. “Commercial use” means all other uses, including use for commercial, or rental purposes. Once in commercial use,
the engine will thereafter be considered a commercial use engine for the purposes of this warranty.
Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044, or at a service
facility designated by us of such parts as inspection shall disclose to have been defective.
EXCLUSIONS:
Mufflers on engines used commercially (non-residential) are warranted for 90 days from date of purchase.
This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide reasonable and
necessary maintenance.
The following items are not covered by this warranty:
Engine accessories such as fuel tanks, clutches, transmissions, power-drive assemblies, and batteries, unless supplied or installed by Kohler Co. These
are subject to the warranties, if any, of their manufacturers.
KOHLER CO. AND/OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY
KIND, including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts.
IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE
EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other express warranty, nor is any one authorized to make
any on our behalf.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the
above limitation or exclusion may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
TO OBTAIN WARRANTY SERVICE:
Purchaser must bring the engine to an authorized Kohler service facility. To locate the nearest facility, visit our website, www.kohlerengines.com, and click
on SALES AND SERVICES to use the locator function, consult your Yellow Pages or telephone 1-800-544-2444.
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
4
KOHLER COURAGE PROTM SV810-840 ENGINE LIMITED WARRANTY
Kohler Co. warrants to the original retail consumer that each new COURAGE PROTM engine sold by Kohler Co. will be free from manufacturing defects in
materials or workmanship in normal residential homeowner service for a period of two (2) years from date of purchase, provided it is operated and maintained
in accordance with Kohler Co.’s instructions and manuals. If used commercially the COURAGE PROTM engine is covered by a one (1) year limited warranty.
The warranty period begins on the date of purchase by the original retail consumer or commercial end user. “Residential homeowner service” means residential
use by a retail consumer. “Commercial use” means all other uses, including use for commercial, or rental purposes. Once in commercial use, the engine will
thereafter be considered a commercial use engine for the purposes of this warranty.
Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044, or at a service facility
designated by us of such parts as inspection shall disclose to have been defective.
EXCLUSIONS:
Mufflers on engines used commercially (non-residential) are warranted for 90 days from date of purchase.
This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide reasonable and
necessary maintenance.
The following items are not covered by this warranty:
Engine accessories such as fuel tanks, clutches, transmissions, power-drive assemblies, and batteries, unless supplied or installed by Kohler Co. These are
subject to the warranties, if any, of their manufacturers.
KOHLER CO. AND/OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND,
including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts.
IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE
EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other express warranty, nor is any one authorized to make any on
our behalf.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
TO OBTAIN WARRANTY SERVICE:
Purchaser must bring the engine to an authorized Kohler service facility. To locate the nearest facility, visit our website, www.kohlerengines.com, and click on
SALES AND SERVICES to use the locator function, consult your Yellow Pages or telephone 1-800-544-2444.
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
COMMAND PRO/Command/Magnum/OHC Warranty Statement
Limited 2 Year COMMAND PRO/Command/Magnum/OHC Engine Warranty
Kohler Co. warrants to the original consumer that each new COMMAND PRO/Command/Magnum/OHC engine sold by Kohler Co. will be free from
manufacturing defects in materials or workmanship in normal service for a period of two (2) years from date of purchase, provided it is operated and maintained
in accordance with Kohler Co.’s instructions and manuals.
Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044, or at a service facility
designated by us of such parts as inspection shall disclose to have been defective.
EXCLUSIONS:
Mufflers on engines used commercially (non-residential) are warranted for one (1) year from date of purchase, except catalytic mufflers, which are warranted for
two (2) years.
This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide reasonable and
necessary maintenance.
The following items are not covered by this warranty.
Engine accessories such as fuel tanks, clutches, transmissions, power drive assemblies, and batteries, unless supplied or installed by Kohler Co. These are
subject to the warranties, if any, of their manufacturers.
KOHLER CO. AND/OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND,
including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts.
IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE
EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other express warranty, nor is anyone authorized to make any on
our behalf.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
TO OBTAIN WARRANTY SERVICE:
Purchaser must bring the engine to an authorized Kohler service facility. To locate the nearest facility, visit our website, www.kohlerengines.com, and click on
SALES AND SERVICE to use the locator function, consult your Yellow Pages or telephone 1-800-544-2444.
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
5
K-Series Warranty Statement
Limited 1 Year Engine Warranty
We warrant to the original consumer that each new engine sold by us will be free from manufacturing defects in materials or workmanship in normal
service for a period of one (1) year from date of purchase, provided it is operated and maintained in accordance with Kohler Co.’s instructions and
manuals.
Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044, or at a service
facility designated by us, of such part or parts as inspection shall disclose to have been defective.
EXCLUSIONS:
Mufflers on engines used commercially (non-residential) are warranted for one (1) year from date of purchase, except catalytic mufflers, which are
warranted for two (2) years.
This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide reasonable and
necessary maintenance.
The following items are not covered by this warranty:
Engine accessories, such as fuel tanks, clutches, transmissions, power drive assemblies, and batteries, unless supplied or installed by Kohler Co. These
are subject to the warranties, if any, of their manufacturers.
WE SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND, including but not limited to
labor costs or transportation charges in connection with the replacement or repair of defective parts.
ANY IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE
EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other express warranty, nor is anyone authorized to make any
in our behalf.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the
above limitation or exclusion may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
TO OBTAIN WARRANTY SERVICE:
Purchaser must bring the engine to an authorized Kohler service facility. For the facility nearest you, consult your Yellow Pages under ‘‘Engines-Gasoline’’
or phone 1-800-544-2444.
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
Service Parts Warranty
Limited 90 Day Service Parts Warranty
We warrant to the original consumer that each new service part sold by us will be free from manufacturing defects in materials or workmanship in normal
service for a period of 90 days* from date of purchase, provided it is installed properly and the engine maintained in accordance with Kohler Co.’s
instructions and manuals.
Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044, or at a service
facility designated by us, of such part or parts as inspection shall disclose to have been defective.
EXCLUSIONS:
This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide reasonable and
necessary maintenance.
The following items are not covered by this warranty:
Engine accessories, unless supplied or installed by Kohler Co. These are subject to the warranties, if any, of their manufacturers.
WE SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND, including but not limited to,
labor costs or transportation charges in connection with the replacement or repair of defective parts.
ANY IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE
EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other express warranty, nor is anyone authorized to make any
in our behalf.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the
above limitation or exclusion may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
TO OBTAIN WARRANTY SERVICE:
Purchaser must bring the service parts to an authorized Kohler service facility. For the facility nearest you, consult your Yellow Pages under ‘‘EnginesGasoline’’ or phone 1-800-544-2444.
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
*One-year limited warranty for long blocks.
6
KOHLER CO.
FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS
LIMITED WARRANTY
SMALL OFF-ROAD ENGINES
The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Kohler Co. are pleased to explain the
Federal and California Emission Control Systems Warranty on your small off-road equipment engine. In California beginning in 2006 "emissions"
means both exhaust and evaporative emissions. For California, engines produced in 2006 and later must be designed, built and equipped to
meet the state’s stringent anti-smog standards. In other states, 1997 and later model year engines must be designed, built and equipped, to
meet the U.S. EPA regulations for small non-road engines. The engine must be free from defects in materials and workmanship which cause it
to fail to conform with U.S. EPA standards for the first two years of engine use from the date of sale to the ultimate purchaser. Kohler Co. must
warrant the emission control system on the engine for the period of time listed above, provided there has been no abuse, neglect or improper
maintenance.
The emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and catalytic converter. Also
included are the hoses, belts and connectors and other emission related assemblies.
Where a warrantable condition exists, Kohler Co. will repair the engine at no cost, including diagnosis (if the diagnostic work is performed at an
authorized dealer), parts and labor.
MANUFACTURER’S WARRANTY COVERAGE
Engines produced in 2006 or later are warranted for two years in California. In other states, 1997 and later model year engines are warranted for
two years. If any emission related part on the engine is defective, the part will be repaired or replaced by Kohler Co. free of charge.
OWNER’S WARRANTY RESPONSIBILITIES
(a) The engine owner is responsible for the performance of the required maintenance listed in the owner’s manual. Kohler Co. recommends
that you retain all receipts covering maintenance on the engine, But Kohler Co. cannot deny warranty solely for the lack of receipts or for
your failure to assure that all scheduled maintenance was performed.
(b)
Be aware, however, that Kohler Co. may deny warranty coverage if the engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
(c)
For warranty repairs, the engine must be presented to a Kohler Co. service center as soon as a problem exists.
Call 1-800-544-2444 or access our web site at: www.kohlerengines.com, for the names of the nearest service centers. The warranty
repairs should be completed in a reasonable amount of time, not to exceed 30 days.
If you have any questions regarding warranty rights and responsibilities, you should contact Kohler Co. at 1-920-457-4441 and ask for an Engine
Service representative.
COVERAGE
Kohler Co. warrants to the ultimate purchaser and each subsequent purchaser that the engine will be designed, built and equipped, at the time
of sale, to meet all applicable regulations. Kohler Co. also warrants to the initial purchaser and each subsequent purchaser, that the engine is
free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a period of two years.
Engines produced in 2006 or later are warranted for two years in California. For 1997 and later model years, EPA requires manufacturers to
warrant engines for two years in all other states. These warranty periods will begin on the date the engine is purchased by the initial purchaser. If
any emission related part on the engine is defective, the part will be replaced by Kohler Co. at no cost to the owner. Kohler Co. is liable for
damages to other engine components caused by the failure of a warranted part still under warranty.
Kohler Co. shall remedy warranty defects at any authorized Kohler Co. engine dealer or warranty station. Warranty repair work done at an
authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective.
Continued on next page.
7
Listed below are the parts covered by the Federal and California Emission Control Systems Warranty. Some parts listed below may require
scheduled maintenance and are warranted up to the first scheduled replacement point for that part. The warranted parts include the following if
they were present in the engine purchased:
•
•
•
•
•
•
•
•
•
Oxygen sensor (if equipped)
Intake manifold (if equipped)
Exhaust manifold (if equipped)
Catalytic muffler (if equipped)
Thermal reactor muffler (if equipped)
Fuel lines, fuel line fittings and clamps (if equipped)
Spark advance module (if equipped)
Crankcase breather
Air Injection System (if equipped)
- Air pump or pulse valve assembly (if equipped)
- Control/distribution valve (if equipped)
- Distribution manifold (if equipped)
- Air hoses (if equipped)
- Vacuum lines (if equipped)
•
•
•
•
•
•
•
Ignition module(s) with high tension lead
Gaseous fuel regulator (if equipped)
Electronic control unit (if equipped)
Carburetor or fuel injection system
Fuel metering valve (if equipped)
Air filter, fuel filter, and spark plugs (only
to first scheduled replacement point)
Evaporative System (if equipped)
- Canister (if equipped)
- Canister filter (if equipped)
- Vapor hose (if equipped)
- Orifice connector (if equipped)
- Fuel tank (if equipped)
- Fuel cap (if equipped)
- Primer bulb canister (if equipped)
LIMITATIONS
This Emission Control Systems Warranty shall not cover any of the following:
(a)
repair or replacement required because of misuse or neglect, improper maintenance, repairs improperly performed or replacements not
conforming to Kohler Co. specifications that adversely affect performance and/or durability and alterations or modifications not
recommended or approved in writing by Kohler Co.,
(b)
replacement of parts and other services and adjustments necessary for required maintenance at and after the first scheduled replacement
point,
(c)
consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc.,
(d)
diagnosis and inspection fees that do not result in eligible warranty service being performed, and
(e)
any add-on or modified part, or malfunction of authorized parts due to the use of add-on or modified parts.
MAINTENANCE AND REPAIR REQUIREMENTS
The owner is responsible for the proper use and maintenance of the engine. Kohler Co. recommends that all receipts and records covering the
performance of regular maintenance be retained in case questions arise. If the engine is resold during the warranty period, the maintenance
records should be transferred to each subsequent owner. Kohler Co. reserves the right to deny warranty coverage if the engine has not been
properly maintained; however, Kohler Co. may not deny warranty repairs solely because of the lack of repair maintenance or failure to keep
maintenance records.
Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or
individual; however, warranty repairs must be performed by a Kohler authorized service center. Any replacement part or service that is
equivalent in performance and durability may be used in non-warranty maintenance or repairs, and shall not reduce the warranty obligations of
the engine manufacturer.
8
Section 3 – Warranty Procedures
A. Service Information Record (SIR)
A Service Information Record must be on file at Kohler
Co. before a service account will be authorized to do
warranty repairs.
Failure to supply or provide a correct Fed. I.D. or Social
Security number will result in a 20% net withholding
payable to the IRS.
Important: Section 6109 of the IRS Code requires
recipients of payments to give their identifying number to
payers.
The Service Information Record is an electronic form that
is available in our electronic parts lookup system, Kohler
PLUS. You must login to Kohler PLUS with your user
name and password to see the SIR form.
9
B. Warranty Repair Authorization
Only registered Kohler Service Accounts are authorized
to perform Kohler engine warranty repairs. A Service
Information Record form must be completed and on file
at Kohler Co. before a service account will be authorized
to do warranty repairs. These forms are to be submitted
through your Central Distributor.
To change your Retail Labor Rate or Warranty Discount
information, have your Central Distributor complete a
new Service Information Record and submit the updated
information to Kohler Co. Change to the Retail Labor
Rate or Warranty Discount must be received at Kohler
Co., Kohler, Wisconsin, 30 days prior to the effective
date of change.
The information on the Service Information Record will
be used by Kohler Co. for warranty processing and
update mailings. If any of the information changes
(company name, address, ownership, key personnel,
etc.), be certain to notify your Central Distributor, so they
can update their records. They will submit the updated
data to Kohler Co.
C. Manufacturing Defects Covered
The warranty applies to repair and replacement of
defective parts caused by faulty material and/or
workmanship in manufacture. It does not apply to defects
caused by negligence in servicing or operating an
engine.
The following conditions cannot be considered under
warranty:
•
•
•
•
•
•
•
•
Normal wear.
Routine tune-up or adjustment.
Damage due to improper handling or accident.
Damage due to operating at speeds or load
conditions contrary to published specifications.
Damage due to improper or insufficient lubrication.
Damage from overheating due to clogged air intake
and cooling fins.
Damage caused by improperly serviced or
inadequate air cleaner.
Damage due to improper storage.
D. Major Warranty Repair
Repairs that require a new short block, miniblock, or
engine must be approved by a Central Distributor
representative for non-expert dealers, or a certified
Expert Dealer, and require that section one of the Engine
Inspection Data Record be completed before such
approval is requested or granted (see Section 8). A new
short block or engine can only be used for a warranty
repair if the engine has clearly failed due to an
identifiable defect in materials or workmanship. In
addition, the engine must either be damaged beyond
repair, or the cost of the repair must have been
10
calculated to exceed 90% of the cost of the short block
or engine to be used.
If an engine or short block is desired for reasons not
explained above, this approval must be provided by a
certified Central Distributor representative. Regardless of
the circumstances, the failed engine or block must be
retained or returned to the authorizing party. If the
replacement guidelines explained above have been met
and/or appropriate approval has been received, promptly
repair the engine and submit a properly filled in Warranty
Claim Report (see Section 6) to Kohler Co. within 30
days after making the repair. Warranty claims for
engines and short blocks must be accompanied by a
copy of the original invoice to verify the actual engine and
shipping costs (this documentation can either be
attached to the online warranty form or faxed to Kohler at
920-459-1743). Warranty claims authorized by Expert
Dealers must be submitted online with a copy of the
claim going to the appropriate Central Distributor
representative. Note: An engine or short block
replacement may be done in advance of the needed
preapproval as long as the customer is aware that they
may be responsible for the repair cost depending on the
findings by Central Distributor or factory representative.
E. Carburetor Warranty Replacement
Warranty claims for carburetor replacements must
include the use of the Carburetor Replacement
Evaluation Form (TP-2570, shown on page 30). This
form must be filled out each time a warranty claim is
submitted for a replacement carburetor. Hard copies of
this form can be made and submitted along with the
paper claims or an electronic version of the form can be
completed online and submitted as an attachment with
the online warranty claim form. Any claims submitted
without this form attached will be returned.
F. Retaining Failed Parts
A claim number is imprinted on each Warranty Claim
Report. Tag all parts replaced under a particular warranty
claim with the corresponding claim number and keep
those parts until you have received your warranty
reimbursement. Kohler Co. may request return of some
parts for study, but if specific instructions are not given
prior to receipt of your reimbursement check, the failed
parts may be discarded.
NOTE: Do not return failed parts unless you have
received instructions and an Engine Warranty
Return (EWR) Number from the Kohler Co.
G. Return of Failed Parts
When Kohler Co. does request the return of failed parts,
formal instructions, plus a label with an EWR Number,
will be issued to the service account involved. This label
must be used to return the part or parts requested. The
instructions will include directions for the return shipment.
NOTE: Do not return failed parts unless you have
received instructions and an EWR Number from
the Kohler Co.
Keep a record of the EWR Number for future
reference.
H. Disputed, Questionable, Unusual Warranty, or
Policy Adjustments
In the event a customer requests or insists on a warranty
repair that, in your opinion, is not covered by the Kohler
Limited Engine Warranty, offer the customer one of the
following options:
1. Repair the engine and charge the customer with the
understanding that you will issue reimbursement, if
the claim is approved. Complete a Warranty Claim,
(see Section 6), and an Engine Inspection Data
Record (TP-2435), and have the damaged parts
reviewed by your Central Distributor representative.
If the claim is approved, have the Central Distributor
representative note authorization for the repair,
reimburse the customer for the charges, and send
the completed Warranty Claim and Engine
Inspection Data Record to Kohler Co., Engine
Warranty, Kohler, WI 53044 for payment.
2. If the customer is willing to wait for a warranty
decision prior to having the services performed,
complete a Warranty Claim, and an Engine
Inspection Data Record. Have your Central
Distributor representative review the failed parts,
Warranty Claim, and Engine Inspection Data
Record. If the claim is approved, have the
representative note authorization for the repair,
perform the repair, and send the completed
Warranty Claim and Engine Inspection Data Record
to Kohler Co., Engine Warranty, Kohler, WI 53044
for payment.
NOTE: If you are located outside the continental
U.S., send only the completed Warranty
Claim and Engine Inspection Data Record
to Kohler Co., Engine Warranty, Kohler, WI
53044. If the failed parts are needed to
make the warranty decision, Kohler Co. will
contact you with specific instruction
concerning the return of the failed parts.
4. If a customer insists on warranty coverage for a
situation you feel is not covered by the standard
policy, contact the Central Distributor for a “Policy
Adjustment” Authorization. The Central Distributor
must fill out and sign the Policy Adjustment
Explanation Form (TP-2466-A shown on page 29)
and attach it to the Warranty Claim.
Kohler Co. will advise you regarding its decision. If the
repair in question is determined to be covered by
warranty, payment will be made. If the customer has
already paid for the repair, issue reimbursement for all
charges paid relating to the Kohler engine warranty.
If, for some reason, the request for warranty
consideration is denied, or a partial allowance is offered,
you will be advised of our findings, along with the
reasons for our decision.
I. Engines Manufactured Over 3 Years Ago
A verification of the date of purchase (Example: Bill of
Sale, Receipt or Invoice) must accompany the Warranty
Claim for all engines that are 3 or more years old. The
chart on the next page will aid in determining the year of
manufacture.
3. If the customer insists on a decision by Kohler Co.,
complete an Engine Inspection Data Record and a
Warranty Claim. Check the “DISPUTED
WARRANTY” box at the top of the claim. Contact
the Kohler Service Department for an EWR Number.
This number should be placed on the outside of the
return carton. Send the completed Warranty Claim,
Engine Inspection Data Record, and the relevant
engine parts, freight prepaid, to Kohler Co., Engine
Warranty – Disputed Claim, Bldg. 604, Kohler, WI
53044.
11
Serial Number Significance
Year of Manufacture identified by:
1. A Letter
2. First Two Digits/
If Seven Digit
Number
3. First Two Digits/If Eight
or Ten Digit Number
E-172452
9276430
10026692
A
B
C
D
E
1965
1966
1967
1968
1969
10-19
20-29
30-39
40-49
50-59
60-69
70-72
73-79
80-89
90-94
95-99
1969
1970
1971
1972
1973
1974
1975
1976
1977
1978
1979
10
11
12
13
14
15
16
17
18
19
20
21
22
1980
1981
1982
1983
1984
1985
1986
1987
1988
1989
1990
1991
1992
Remaining digits are
a factory code.
1501897591
23
24
25
26
27
28
29
30
31
32
33
34
35
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
36
37
38
2006
2007
2008
Section 4 – Warranty Service Parts
A. Policy
Service parts, short blocks, miniblocks, and accessory
kits are warranted against manufacturing defects in
workmanship and material for a period of 90 days from
date of purchase by the original user.
B. Defective Service Parts (New Inventory)
When a part from new service part inventory is found to
be defective in material or workmanship, file a Warranty
Claim as described in Section 6.
Short blocks, miniblocks, and engines must have Central
Distributor approval for non-expert dealers, or certified
Expert Dealer approval with signatures.
Transportation costs for parts replacement will not be
reimbursed. Unless required by individual state.
C. Defective Service Parts (Installed)
If a new service part was installed by an authorized
Kohler service outlet, and failed within 90 days after
installation, submit a Warranty Claim for parts and labor
as described in Section 6.
For service parts installed by persons other than
authorized Kohler service outlets, and failed within 90
days from date of purchase, submit a Warranty Claim
and proof of purchase for the defective part only (no
labor), as described in Section 6.
Short blocks, miniblocks, and engines must have Central
Distributor approval for non-expert dealers, or certified
Expert Dealer approval with signatures.
12
If the defective new parts are components of an
assembly, repair the assembly by replacing the defective
parts whenever this is economically feasible. For
example, if the bearing plate on a short block assembly
is cracked, due to obvious material defect, replace the
bearing plate and submit a warranty claim for the repair.
D. Defective Service Parts (Installed During Engine
Warranty Period)
Warranty coverage for components installed during an
engine warranty period shall consist of the duration of the
engine warranty coverage*** or 90 days, whichever is
greater, provided the warranty installation is performed
by an authorized Kohler service outlet.
E. Warranty Options and Accessories
1. Options (Factory Installed)
All factory installed options are warranted against
defects in workmanship or material for the normal
engine warranty period.***
2. Accessories (Field Installed)
All field installed accessories are warranted against
defects in material and workmanship for the
duration of the engine warranty period*** or 90 days,
whichever is greater, provided the installation was
performed by an authorized Kohler service outlet.
***Except consumable items such as mufflers and
maintenance items.
Section 5 – Warranty Exclusion
A. Non-Reimburseable Items
1. Repairs required to correct failures caused by
neglect, normal wear, improper lubrication or abuse.
Kohler Co. warranty covers defective workmanship
and materials only.
2. Parts and labor supplied by the user or any
unauthorized repair facility.
3. Normal maintenance, adjustments, or consumable
items, such as fuel, spark plugs, filters, lubricating
oil, and hoses.
5. Rental of another engine or other related equipment
while engine repairs are in progress.
6. Telephone, facsimile, and/or other related
communications expenses.
7. Replacement and accessory parts not supplied by
Kohler Co. and damages resulting from their
installation.
8. Loss of revenue resulting from the failure.
9. Loss or damage to personal property.
4. Parts and accessories not installed or supplied by
Kohler Co.
10. Transportation charges accrued during
transportation of failed unit or equipment.*
*Expert classifications are exempt.
Section 6 – Claims Procedure
NOTE: Warranty Claims received without required information WILL BE RETURNED!
A. Responsibility for Submitting Proper and
Completed Warranty Claim Forms
Warranty repairs and completion of properly filled out
warranty claim forms are the responsibility of the
authorized service outlet. It is the responsibility of the
service outlet to review each claim for thoroughness,
authenticity, and accuracy of information. Warranty
claims will not be considered complete unless all the
information requested on the claim form is filled in.
Incomplete or inaccurate claims will be returned to the
service outlet. Claim forms received more than 30 days
after warranty repairs are completed will not be accepted.
Complete engines, short blocks, and miniblocks must
have Central Distributor approval for non-expert dealers,
or certified Expert Dealer approval with signatures. When
authorized, the signature of the person authorizing, and
date, must be on the warranty claim.
B. Warranty Claim Report Forms
Three different Warranty Claim Report Forms are
accepted by Kohler Co. – the OPEESA (Outdoor Power
Equipment and Engine Service Association), the OPEI
(Outdoor Power Equipment Institute), and Electronic.
The electronic Warranty Claim is available in Kohler
PLUS. You must login to Kohler PLUS with your user
name and password to see the electronic Warranty
Claim.
The OPEESA Warranty Claim Form is illustrated, and
instructions for completing it are given. Please follow the
instructions when making out the report. Do not combine
claims for more than one repair on a single form – each
claim must be filed separately. Claims must be received
at Kohler Co. within 30 days after warranty repairs are
made. Send the white copy of the paper claim directly to
Kohler Co., Engine Warranty, Kohler, WI 53044, except
in cases where Central Distributor approval for nonexpert dealers, or certified Expert Dealer approval is
required. (See Section A.)
C. Warranty Claim Instructions
The Outdoor Power Equipment and Engine Service
Association, in conjunction with the manufacturers who
use it, have developed the following warranty claim form.
Follow these instructions when filling out a paper claim.
13
Box 1: Check box for type of claim and manufacturer.
Box 2: Enter Warranty Code Number.
Box 3: Enter engine owner’s name, address, and have
owner sign.
Box 4: Enter name of repairing dealer, check box for
type of dealer, have technician sign. Enter dates as
requested.
Box 5: For regular Engine Warranty Claim – fill in
completely, giving all information requested.
A. Parts new defective in stock – Enter “parts” in
engine/transmission model number section and
leave the remaining sections blank.
C. Parts, short block, or miniblock found defective
within 90 days after installation – Enter parts/
engine model number (Example: Parts/M8) in
engine/transmission model number section. For a
miniblock or short block, list the part number in the
type or spec. number section. List the serial number
of the defective short block or miniblock in the code
or serial number section and complete the
remaining sections.
NOTE: Boxes 1, 2, 4, 8, and 16 are required for
defective service parts. In addition, box 17 must
be signed by a Central Distributor representative
for non-expert dealers, or a certified Expert
Dealer for short block, miniblock, or engine
replacement.
Box 6: Record hours used.
B. Short block or miniblock new defective in
stock – Enter “parts” in engine/transmission model
number section. List the defective assembly part
number in the type or spec. number section. List the
serial number in the code or serial number section.
Leave the remaining sections blank.
14
Box 7: Enter name of original seller of equipment.
Box 8: Check box describing parts disposition.
Box 9: Enter part number of defective part.
The part number should normally not be an assembly part
number. The actual part number of the component within
an assembly that failed should be shown. For example, a
wrist pin retainer failure caused extensive damage to the
cylinder bore requiring a miniblock assembly. The Kohler
Engine Failure code in this case would be the part number
of the retainer, 235811. You would not enter the miniblock
assembly number in this case.
4000 for removing and reinstalling (R & R) as a separate
item. Check against the flat rate maximums.
The only time an assembly number should be entered is
when no parts breakdown is given for the failed assembly
(Example: a magnet came loose on a flywheel. There is
no service part number for the flywheel magnet, therefore,
the part number for the flywheel would be listed).
Important: Using the incorrect Flat Rate Schedule could
result in incorrect payment and/or delay in the processing of
your claim.
Box 10: Enter failure suffix from listing on claim, also
shown below.
Box 14: Enter labor time in hours and decimal fractions
(Example: 1.5).
Box 11: Conditions Found – Describe in detail the failure.
If more space is required attach a note.
Box 15: Leave blank – factory use only.
Probable Cause of Failure – List in detail the most
probable cause.
Box 12: Enter the job numbers of work performed as
stated in the Flat Rate Schedule and indicate time spent in
repairing the engine. When it becomes necessary to
remove an engine to make the repair, enter job number
The flat rate times have been established using facilities
and equipment that all Service Accounts should have
available. If your repair time exceeds the flat rate, and
additional labor allowance is requested, please send a note
of explanation so consideration can be given.
Box 13: Fill in freight allowance details if applicable.
Box 16: List part numbers and description of each part
replaced.
Box 17: Must be filled in and signed by a Central
Distributor representative for non-expert dealers, or a
certified Expert Dealer when any short block, miniblock, or
engine is replaced. An Engine Inspection Data Record
(TP-2435) should be completed and submitted with the
Warranty Claim.
Failure Type Suffix
AW
BC
BL
BT
CD
CL
CP
DE
EF
FM
IF
Assembled Wrong
Broken/Cracked
Blown
Bent/Twisted
Porous/Casting Deficiency
Came Loose/Off
Corroded/Pitted
Dented
Electric Failure
Foreign Material
Improper Fit
LK
MI
ML
NS
NY
OA
OB
PK
PM
PP
SD
Leaked
Missing
Magnets Loose
Not Seating
Noisy
Out of Adjustment
Out of Balance
Packing Material Defective
Part Made/Machined Incorrectly
Paint Peeling
Shipping Damage
SG
SS
ST
TR
UO
VC
WW
WN
WP
ZZ
Scored/Galled
Stuck/Seized
Stripped
Trucking Damage
Unknown/Other
Valve/Clearance
Weak Weld
Worn
Warped
Others
Section 7 – Reimbursement Procedures
A. Policy
Kohler Co. will reimburse only registered service outlets
for warranty services performed provided a completed
warranty claim is submitted and approved. Method of
reimbursement is by direct check within the United States
or Canada. International service outlets will be
reimbursed through their local Central Distributor.
B. Reimbursement Calculation Details
Warranty reimbursement is calculated by using the
following formulas for each worldwide service outlet
classification.
1. U.S.A. & CANADA, NON-EXPERT
Standard Warranty Repair - Parts and Labor (no engines)
Total Credit = Net price of replacement part +
Parts Profit (a),(b),(c),(d) + Posted Full Shop Labor Rate
(U.S. dollars) + Miscellaneous Costs (e) +
Freight (short blocks & miniblocks only, see section C).
(a) Parts Profit % may vary depending on individual state
regulation.
(b) Short Blocks or Miniblocks = 10%.
(c) Parts Profit for Authorized Service Outlet = 20%.
(d) Parts Profit for Specialized Service Outlet = 10%.
(e) Miscellaneous Cost = Cylinder honing and crankshaft
grinding.
15
Standard Warranty Repair - Engine and Labor
Total Credit = List price of replacement Command,
Courage, Aegis series engine less 10% (f) + Parts
Profit (g) + Freight (see section C) + Posted Full Shop
Labor Rate (U.S. dollars) + Miscellaneous Costs (e).
(e) Miscellaneous Cost = Cylinder honing and
crankshaft grinding.
(f) K-Series and Magnum engines use net price.
(g) Profit on parts for K-Series and Magnum engines +
10%.
Standard Warranty Repair - Engine and Labor
Total Credit = List price of replacement Command,
Courage, Aegis series engine less 10% (f) + Parts
Profit (g) + Posted Full Shop Labor Rate (U.S. dollars) +
Miscellaneous Costs (e) + Handling Allowance.
(e) Miscellaneous Cost = Cylinder honing and
crankshaft grinding.
(f) K-Series and Magnum engines use net price.
(g) Profit on parts for K-Series and Magnum engines +
10%.
2. U.S.A. & CANADA, EXPERT
4. INTERNATIONAL, EXPERT
All Standard Warranty Repairs
Total Credit = List price of replacement engine or parts +
Freight + Posted Full Shop Labor Rate (U.S. dollars) +
Miscellaneous Costs + Diagnostic + Incidentals (Kohler
parts only).
All Standard Warranty Repair
Total Credit = List price of replacement engine or parts +
Freight (emergency stock code 4 or 5 only) + Posted Full
Shop Labor Rate (U.S. dollars) + Miscellaneous Costs +
Diagnostic + Incidentals (Kohler parts only).
3. INTERNATIONAL, NON-EXPERT
C. Freight Cost U.S.A & Canada (FOB and Truck)
Freight costs for warranty work will be reimbursed where
a short block, miniblock, or service engine is required.
Submit a warranty claim form and a copy of the freight
bill. No transportation costs for individual parts will be
reimbursed (unless required by individual USA State
regulations).
Standard Warranty Repair - Parts and Labor (no
engines)
Total Credit = Net price of replacement part + Parts Profit
(b),(c),(d) + Posted Full Shop Labor Rate (U.S. dollars) +
Miscellaneous Costs (e) + Handling Allowance.
(b) Short Blocks or Miniblocks = 10%.
(c) Parts Profit for Authorized Service Outlet = 20%.
(d) Parts Profit for Specialized Service Outlet = 10%.
(e) Miscellaneous Cost = Cylinder honing and
crankshaft grinding.
When shipped by a distributor and a freight bill is not
available, list in box 13 the FOB charges you received
from your distributor and have the Central Distributor
representative initial the charge.
Section 8 – Engine Inspection Data Record
A. Engine Inspection Data Record Instructions
Engine Inspection Data Record (TP-2435) must be
completed for the following situations: policy
adjustments, disputed warranty, or when a short block,
miniblock, or engine is required.
1. If the Service Distributor or Expert classified outlet
representative cannot make a final decision, due to
inconclusive evidence or information. Assistance
from the Central Distributor or factory will be
required.
Section 1 of the Engine Inspection Data Record should
be filled in immediately, when you receive an engine that
has had a major failure within the warranty period. If
possible, review it while the customer is still present, as
you will probably need their input to answer some of the
questions. Section 1 should be completed and ready for
your distributor representative when they arrive to make
their analysis.
2. If the engine is on a piece of commercial equipment
more than six months old, and/or the engine has
more than 500 hours of running.
Section 2 should be completed, at the time the distributor
representative makes their review and analysis, and in
the following situations.
16
3. If the engine has not yet reached the above criteria
(less than six months old, less than 500 hours), you
need only complete that portion of Section 2 which
pertains to the actual failure. For example, if the
connecting rod has seized to the crankshaft you
would only fill out the "Connecting Rod", "Crankshaft
Rod Journal", and "Evaluation Performed By"
segments of Section 2. However, if you notice
anything else that could have been a contributing
factor, such as burned oil deposits on the piston
(indicating possible overheating and/or oil
breakdown), that should also be noted.
B. Engine Inspection Data Record
Engine Inspection Data Record
To facilitate accurate evaluation:
• enter as much information as possible
• provide as many dimensions as possible.
SECTION 1
• mark location of break or crack on drawing
• record conditions found with check mark (X) whenever possible
OWNER AND EQUIPMENT INFORMATION
Owner's Name
Street Address
City
State
Zip Code
Phone No.
(
Model No.
Spec. No.
)
-
Serial No.
Manufacturer of Equipment
Type Equipment
Date Failed
Date Purchased
Previous Repairs
Times Used
Hours Used
Warranty Claim No.
YES
NO
USAGE/MAINTENANCE INFORMATION
10W-30
10W-40
Oil type:
30W
5W-20
5W-30
Hours since last oil change?
Other
Must oil be added between changes?
How often is the oil level checked?
Every time
Never
Other
Yes
Yes
No
Was it ever replaced or cleaned?
Element
How recently?
Yes
No
Element:
Yes
Precleaner
No
Element
By whom?
Were any adjustments made to the carburetor or governor?
Yes
No
How much?
Precleaner
What brand?
Precleaner:
No
How often is the air cleaner checked?
Was an oil additive used?
Customer
If yes, specify
Dealer
PRELIMINARY EXAMINATION
Air Cleaner Assembly
Type:
Dry
Precleaner
Remote
1. Wing Nut:
Oil Bath
Tri-Phase
Wing nut seal:
Factory Original
Non-standard replacement
Intact
Separated
Missing
2. Outer Cover:
Good condition
Center hole oblong
Other damage (specify)
3. Precleaner:
Clean
Dirty
Plugged
Oiled
Dry
Torn
Other damage
4. Inner Cover:
Retaining seal/nut in place
Center hole oblong
Distorted
Other damage
5. Element:
Clean
Dusty
Dirty
Plugged
Missing
Dry
Non-factory replacement
Other damage
6. Element seals:
Pliable
Hard
Sealing
Leaking
Other damage
7. Air cleaner base:
Tight
Loose
Screw(s) missing
Distorted/Cracked
Breather hose detached
Other damage
Crankcase Oil
1. Amount on dipstick:
Overfilled
Full
Above ‘‘add’’
Below ‘‘add’’
No reading
2. Condition of oil:
New
Used
Dirty
Black
Thick/Sticky
Burnt smelling
Fuel diluted
3. Quantity of oil:
Amount drained:
Amount req'd.
Observations:
Metal chips present
TP-2435
Sludge present
Non-factory oil filter
(Continued on page 2)
17
Preliminary Examination (continued)
Cooling System
1. Flywheel Screen:
2. Cooling fins:
Clean
Plugged
Partially blocked (%)
Clean
Plugged
Partially blocked (%)
3. Engine exterior:
Clean
Dirty
Oily
Evidence of prior disassembly or repair
Visible oil leaks (where)
Carburetor and Fuel Supply
1. Condition of carburetor:
Okay
2. Settings:
Broken
Loose
Shafts worn
Dirt in throat
Main fuel adj.
Idle fuel adj.
3. Condition of fuel:
Clean
Fresh
Stale
Contaminated (water, debris, etc.)
Governor
1. Components:
2. Function:
Intact
Missing
Modified
Bent/Broken
Operative
Inoperative
Modified
Misadjusted
Dirt Ingestion
1. Is there evidence of possible dirty entry via:
Air cleaner
Carburetor
Breather
Gasket/Seal
Oil fill opening
Other
Spark Plug
Spark Plug
Cylinder 1
Gap
Cylinder 2
Combustion Deposits
in.
Cylinder 1
Cylinder 2
Light
in.
Make
Heavy
Number
Color
EVALUATION PERFORMED BY
SECTION 2
Evaluator
Date
Company Name
Type of Acct.
Central Distributor
Expert Dealer
Service Dealer
Address
State
City
Phone No.
Zip Code
TEAR DOWN ANALYSIS
VALVES
CYLINDER 1
Exhaust
Intake
Intake
CYLINDER 2
Exhaust
Stuck
Face Burned
Bent
Guide Worn
Not Damaged
CLEARANCE: (COLD)
CYLINDER 1
CYLINDER 2
PISTON RINGS
Intake
in.
in.
Production Rings
Exhaust
in.
in.
Service Rings
CONNECTING ROD
CYLINDER 1
CYLINDER 2
CYLINDER 2
CYLINDER 1
Rings Free in Grooves
Discolored
Rings Stuck in Grooves
Broken
End Gap:
Top
Center
Oil
Bearing Scored
Cap Screws Loose
Dipper Bent
in.
in.
in.
in.
in.
in.
Dipper Broken
Rod Seized to Crankpin
Note: For Crankshaft, Pistons & Cylinder Bore Measurements –
See Page 3.
Rod OK - Not Damaged
2
18
(Continued on page 3)
Tear Down Analysis (continued)
CRANKSHAFT ROD JOURNAL
CYLINDER 2
CYLINDER 1
Left
Scored
Middle
Right
Worn
Unmeasureable
Broken
Not Damaged
Others
Maximum Wear Spec.
CYLINDER 1
X
Y
X
CYLINDER 2
Y
MAX. OUT OF
ROUND
Y
X
Left
Middle
Right
Max. Taper
PISTON
Select the following piston type and measure diameter using appropriate method.
Style A
Style B
Style D
Style C
1/2"
1/2"
Measure just below oil ring groove and at right angle to
piston pin.
CYLINDER 1
Style E
Measure 1/2 inch above the bottom of the skirt and at right
angle to piston pin.
CYLINDER 2
Scored
Worn
Cracked
Broken
Ring Grooves Worn
Galled
Discolored
Measure 6 mm (0.24 in.)
above the bottom of piston
skirt at right angles to piston
pin.
CYLINDER 1
CYLINDER 2
CYLINDER 1
CYLINDER 2
CYLINDER 1
CYLINDER 2
Scratched
Not Damaged
Others
Piston Diameter
CYLINDER BORE
Bore Scored
Worn
Not Damaged
Others
MAXIMUM WEAR SPEC.
CYLINDER 1
Y
X
X
CYLINDER 2
Y
X
Y
MAX. OUT OF
ROUND
Top
Center
Bottom
Max. Taper
3
19
Section 9 – Flat Rate Schedules
Command Pro CS Series Flat Rate Schedule
Job No.
Maximum Time (Hr.)
CS4-12
4020
4021
4022
4023
4024
Major Repairs
Engine R & R
Engine R & R From Generator Set
Major Overhaul (Includes Valve Service)
Minor Overhaul (Excludes Valve Service)
Connecting Rod
Piston and/or Rings
Crankshaft
Crankshaft & Main Bearing R & R
Crankshaft – PTO Seal
Crankshaft – Flywheel Seal
Crankshaft & Connecting Rod
Balance Shaft – R & R
4028
4029
4030
4031
4033
4034
4035
4039
4046
4047
Camshaft & Valves
Lifters
Valve R & R (No Grinding)
Valve Tappet Adjustment
Valve Grinding
Valve Spring Replacement
Valve Cover Gasket and/or Breather
Camshaft R & R
Rocker Arm
Ignition Module R & R
Flywheel R & R
1.5
1.1
0.2
1.2
0.9
0.3
1.5
0.2
1.0
1.0
4050
Charging
Regulator – Test & Replace
0.5
4051
Major Repairs
Stator – Test & Replace (Includes Flywheel R & R)
1.5
4060
4061
4064
4065
Starter
Retractable – R & R, Replace Rope & Spring
Starting Motor – Bendix Type R & R
Starter Drive R & R
Starter Solenoid R & R
1.0
1.2
0.5
0.5
4070
4071
4072
4073
4074
4076
Carburetor & Air Intake
Carburetor R & R
Carburetor – Rebuild (Includes R & R)
Carburetor – Adjust
Air Cleaner – Damage in Shipment
Fuel Tank – R & R
Intake Manifold
0.5
1.0
0.1
0.1
0.2
0.5
4080
4082
4083
4084
4085
4086
4088
4089
4090
4091
4092
4093
Miscellaneous Repairs
Cylinder Head and/or Gasket – Replace/each
Shrouds only – R & R
Oil Pan, Closure Plate, and/or Gasket –Replace
Muffler – Replace
Governor – Adjustment
Governor R & R
Crankshaft – Grinding (ENTER NET COST)
Crankcase – Boring (ENTER NET COST)
Governor Seal Replacement
Oil Sentry Module
Oil Sentry Float
Gear Reduction R & R
0.8
0.2
1.3
0.2
0.2
1.6
–
–
1.6
0.3
1.5
0.6
4000
4002
4012
4013
4015
4016
20
Description
1.0
1.0
4.0
3.0
2.0
2.0
2.3
1.2
2.2
2.5
1.5
Courage XT-Series, Courage Single &
Command Single Flat Rate Schedule
Job No.
4000
4001
4002
4010
4012
4013
4015
4016
4020
4021
4022
4023
4024
4028
4029
4030
4031
4033
4034
4035
4037
4039
4046
4047
4048
4050
4051
Description
Major Repairs
Engine R & R
Generator Set R & R – Motor Home
Engine R & R From Generator Set
Short Block Replacement
Major Overhaul (Includes Valve Service)
Minor Overhaul (Excludes Valve Service)
Connecting Rod
Piston and/or Rings
Crankshaft
Crankshaft & Main Bearing R & R
Crankshaft – PTO Seal
Crankshaft – Flywheel Seal
Crankshaft & Connecting Rod
Balance Shaft/Weights – R & R
Camshaft & Valves
Lifters
Valve R & R (No Grinding)
Valve Adjustment
Valve Grinding
Valve Spring Replacement
Valve Cover Gasket and/or Breather
Camshaft R & R
Camshaft PTO Seal
Rocker Arm
Ignition
Ignition Module R & R
Flywheel R & R
Spark Advance Module
Charging
Regulator – Test & Replace
Stator – Test & Replace (Includes Flywheel R & R)
4067
4070
4071
4072
4073
4074
4075
4078
Starter
Retractable – R & R, Replace Rope & Spring
Starting Motor – Bendix Type R & R
Starter – Bendix Rebuild (Includes R & R)
Starter Drive R & R
Starter Solenoid R & R
Recoil Cup R & R
Fuel System & Air Intake
Carburetor Solenoid (Includes Test)
Carburetor R & R
Carburetor – Rebuild (Includes R & R)
Carburetor – Adjust
Air Cleaner – Damage in Shipment
Fuel Tank – R & R
Fuel Pump – R & R
Primer Assembly R & R
4080
4082
4083
4084
4085
4086
4087
4088
4089
4090
4091
4096
4106
4108
4109
4110
4111
4112
4113
4114
Miscellaneous Repairs
Cylinder Head and/or Gasket
Blower Housing/Shrouds only – R & R
Oil Pan, Closure Plate, and/or Gasket – Replace
Muffler – Replace
Governor – Adjustment
Governor R & R
Oil Pump R & R
Crankshaft – Grinding (ENTER NET COST)
Crankcase – Boring (ENTER NET COST)
Governor Seal Replacement
Oil Sentry/Oil Temp./Oxygen Sensor
Cam Followers (Includes Valve Adjustment)
Control Bracket R & R
Control Linkage
Dipstick & Tube
Fuel Line and/or Filter
Cooling Fan (Flywheel)
Breather Assembly Repair
Breather Hose R & R
Flywheel Brake Assembly R & R
4060
4061
4063
4064
4065
4066
Maximum Time (Hr.)
XT-6, XT-7
SV470-620
CH5,6
CH11-16
CV11-495
0.4
–
–
–
–
1.0
–
–
1.0
–
–
2.0
–
–
1.8
1.8
1.0
2.0
1.0
1.0
3.0
2.5
2.0
2.0
1.0
2.0
1.0
1.5
4.0
3.0
2.5
2.5
–
0.3
0.4
–
–
1.5
0.3
0.6
–
1.5
2.5
0.5
1.5
2.5
–
3.0
0.5
1.5
2.5
1.5
–
1.0
0.5
1.2
0.3
0.3
–
–
0.5
–
1.2
0.5
–
–
0.3
1.3
–
0.6
–
1.0
0.5
1.2
0.5
0.3
1.5
0.5
0.7
1.0
1.0
–
1.2
1.0
0.5
2.0
–
0.7
0.3
0.4
–
0.3
0.5
–
1.0
1.2
–
1.0
1.2
0.5
–
–
0.5
0.8
–
1.0
0.5
1.5
0.5
–
–
–
–
0.3
–
0.3
1.0
0.7
–
–
1.0
0.5
1.0
1.0
0.5
–
1.0
0.5
1.0
1.0
0.5
–
–
0.3
0.7
0.2
0.3
0.5
–
0.2
0.3
0.5
1.0
0.2
–
–
0.3
–
–
1.0
1.5
0.3
0.5
1.0
0.3
–
0.3
0.5
1.0
0.3
0.3
0.5
0.3
–
0.7
0.2
1.0
0.2
0.2
–
–
–
–
0.3
–
–
0.3
0.3
0.1
0.3
0.3
0.5
0.1
0.4
1.0
0.2
0.8
0.3
0.3
1.1
1.4
–
–
–
0.3
1.3
–
–
–
–
–
–
–
–
1.0
0.5
–
0.3
0.5
1.5
–
–
–
–
0.3
–
–
–
–
–
–
–
–
–
1.0
0.5
1.5
0.3
0.5
2.0
0.5
–
–
0.8
0.2
–
–
–
–
–
–
–
–
–
21
Command Twin & Command PRO Twin
Flat Rate Schedule
Job No.
Description
4046
4047
4048
4049
Major Repairs
Engine R & R
Engine R & R From Generator Set/Welder
Short Block Replacement
Miniblock
Major Overhaul (Includes Valve Service)
Minor Overhaul (Excludes Valve Service)
Connecting Rod
Piston and/or Rings
Crankshaft
Crankshaft & Main Bearing R & R
Crankshaft – PTO Seal
Crankshaft – Flywheel Seal
Crankshaft & Connecting Rod
Camshaft & Valves
Lifters
Valve R & R (No Grinding)
Valve Adjustment
Valve Grinding
Valve Spring Replacement
Valve Cover Gasket and/or Breather
Camshaft R & R
Camshaft PTO Seal
Rocker Arm
Ignition
Ignition Module R & R (Includes Both Modules)
Flywheel R & R
Spark Advance Module/ECU/TPS1
Speed Sensor
4050
4051
4052
Charging
Regulator – Test & Replace
Stator – Test & Replace (Includes Flywheel R & R)
Wiring Harness R & R
4000
4002
4010
4011
4012
4013
4015
4016
4020
4021
4022
4023
4028
4029
4030
4031
4033
4034
4035
4037
4039
4060
4061
4063
4064
4065
4070
4071
4072
4073
4075
4076
4077
Maximum Time (Hr.)
Command PRO Twin
Command Twin
CH18-23
CV17-23
CH/CV730-740 CH/CV25,26
CH/CV750
CH/CV745 CH940-980 CV940-980
Starter
Retractable – R & R, Replace Rope & Spring
Starting Motor – Bendix Type R & R
Starter – Bendix Rebuild (Includes R & R)
Starter Drive R & R
Starter Solenoid R & R
Fuel System & Air Intake
Carburetor R & R
Carburetor – Rebuild (Includes R & R)
Carburetor – Adjust
Air Cleaner – Damage in Shipment
Fuel Pump – R & R
Intake Manifold
Injectors/Fuel Rail

1

A
Time allowed is for each cylinder.
Additional 0.5 for 2nd cylinder.

Additional 0.5 for EFI engines.
22
2.5
4.0
3.0
4.0
5.0
4.0
3.0
3.0
2.5
4.0
3.0
4.0
5.0
4.0
3.0
3.0
2.5
4.0
3.0
–
5.0
4.0
3.0
3.5
2.5
4.0
3.0
–
5.0
4.0
3.0
3.5
3.0
0.5
1.5
3.0
3.0
0.5
1.5
3.0
3.5
0.8
1.5
3.0
3.5
0.8
1.5
3.0
0.5
1.0
–
1.2
1.0
0.5
2.0
–
0.5
0.5
1.0
–
1.2
1.0
0.5
2.0
–
0.5
2.0
2.5
–
1.2
1.0
0.3
2.7
–
0.5
2.0
2.5
0.3
1.2
1.0
0.3
2.7
–
0.5
1.5
1.2
1.0
–
1.5
1.2
1.0
1.0
0.5
0.7
–
–
0.5
0.7
–
–
0.5
1.5
1.0
0.5
1.5
1.0
0.5
1.0
1.0
0.5
1.0
1.0
0.5
1.0
1.0
1.0
0.5
0.5
1.0
1.0
1.0
0.5
–
0.5
1.0
1.0
0.5
–
0.5
1.0
1.0
0.5
0.5†
1.0
0.3
0.3
0.3
1.0
–
0.5
1.0
0.3
0.3
0.5
1.0
1.5
0.5
0.8
1.0
0.3
0.3
1.5
–
0.5
0.8
1.0
0.3
0.3
1.5
–
ECU-Engine Control Unit; TPS-Throttle Position Sensor.
Plated cylinders cannot be rebored.
†
CH/CV750 is 1.0 hr.
Command Twin & Command PRO Twin
Flat Rate Schedule
Job No.
4080
4082
4083
4084
4085
4086
4087
4088
4089
4090
4091
4094
4095
4097
4100
4101
4102
4103
4104
4105
4106
4107
Maximum Time (Hr.)
Command Twin
Description
Miscellaneous Repairs
Cylinder Head and/or Gasket – Replace/each
Shrouds only – R & R
Oil Pan, Closure Plate, and/or Gasket – Replace
Muffler – Replace
Governor – Adjustment
Governor R & R
Oil Pump R & R
Crankshaft – Grinding (ENTER NET COST)
Crankcase – Boring (ENTER NET COST)
Governor Seal Replacement
Oil Sentry/Oil Temp./Oxygen Sensor
Adjust Belt Tension
Flywheel Cover
Breather Cover R & R
Lifter Feed Chamber Cover R & R
Oil Cooler R & R
Oil Filter Housing R & R
Oil Filter Adapter R & R
Backing Plate Shroud Assembly
Valley Baffle R & R
Control Bracket R & R
Oil Reservoir/Gasket R & R
1.0
0.5
1.0
0.3
0.5
1.5
1.5
–
–
0.8
0.3
–
–
2.0
–
–
–
–
–
–
–
–

1

A
Time allowed is for each cylinder.
Additional 0.5 for 2nd cylinder.

Additional 0.5 for EFI engines.
Command PRO Twin
CH18-23
CV17-23
CH/CV730-740 CH/CV25,26
CH/CV750
CH/CV745 CH940-980
1.0
0.5
1.0
0.3
0.5
1.5
1.5
–
A
0.8
0.3
–
–
2.0
–
–
–
–
–
–
–
–
1.2
0.3
1.0
0.3
0.5
1.5
1.5
–
–
1.5
0.3
–
–
0.5
2.5
0.5
0.5
0.5
2.5
0.3
0.5
0.5
CV940-980
1.2
0.3
1.0
0.3
0.5
1.5
1.5
–
–
1.5
0.3
–
–
0.3
2.5
0.5
0.5
–
2.5
0.3
0.5
–
ECU-Engine Control Unit; TPS-Throttle Position Sensor.
Plated cylinders cannot be rebored.
23
Maximum Time (Hr.)
Courage Twin, Courage PRO Twin,
& Aegis Flat Rate Schedule
Job No.
Description
Courage
PRO Twin
SV710-740
SV810-840
LV560-680
LH630-775
Aegis
4000
4002
4010
4011
4012
4013
4015
4016
Major Repairs
Engine R & R
Engine R & R From Generator Set/Welder
Short Block Replacement
Miniblock
Major Overhaul (Includes Valve Service)
Minor Overhaul (Excludes Valve Service)
Connecting Rod
Piston and/or Rings
2.5
–
3.0
4.0
5.0
4.0
3.0
3.0
2.5
–
3.0
4.0
5.0
4.0
3.0
3.0
2.5
–
5.0
6.0
7.0
6.0
5.0
5.0
2.5
–
5.0
6.0
7.0
6.0
4.0
4.0
4020
4021
4022
4023
Crankshaft
Crankshaft & Main Bearing R & R
Crankshaft – PTO Seal
Crankshaft – Flywheel Seal
Crankshaft & Connecting Rod
3.0
0.5
1.5
3.0
3.0
0.5
1.5
3.0
2.5
0.5
1.0
1.5
3.8
1.5
1.6
1.5
4028
4029
4030
4031
4033
4034
4035
4037
4039
Camshaft & Valves
Lifters
Valve R & R (No Grinding)
Valve Adjustment
Valve Grinding
Valve Spring Replacement
Valve Cover Gasket and/or Breather
Camshaft R & R
Camshaft PTO Seal
Rocker Arm
–
1.0
0.5
1.2
1.0
0.5
2.0
–
0.7
–
1.0
0.5
1.2
1.0
0.5
2.0
–
0.7
1.0
3.5
0.5
3.8
3.3
0.5
2.5
1.8
0.5
0.5
2.7
–
3.0
2.5
0.5
2.8
2.1
0.5
4046
4047
4048
4049
Ignition
Ignition Module R & R (Includes Both Modules)
Flywheel R & R
Spark Advance Module/ECU/TPS1
Speed Sensor
0.7
1.2
1.0
–
0.7
1.2
1.0
–
1.5
0.8
–
–
0.7
1.3
1.0
1.0
0.8
1.5
1.0
0.8
1.5
1.0
0.5
1.0
1.0
0.3
1.5
1.0
–
–
–
–
–
–
–
–
–
–
1.0
1.5
0.5
1.7
1.5
0.7
1.0
0.7
2.0
1.8
4055
4056
4057
4058
4059
Charging
Regulator – Test & Replace
Stator – Test & Replace (Includes Flywheel R & R)
Wiring Harness R & R
Cooling System
Coolant R & R (Includes Coolant Temp. Switch)
Radiator R & R
Thermostat R & R
Water Pump
Pump Drive Belt
4060
4061
4063
4064
4065
Starter
Retractable – R & R, Replace Rope & Spring
Starting Motor – Bendix Type R & R
Starter – Bendix Rebuild (Includes R & R)
Starter Drive R & R
Starter Solenoid R & R
–
1.0
1.0
1.0
0.5
–
1.0
1.0
1.0
0.5
–
0.5
1.0
1.0
0.5
–
0.5
1.0
1.0
0.5
4070
4071
4072
4073
4075
4076
4077
Fuel System & Air Intake
Carburetor R & R
Carburetor – Rebuild (Includes R & R)
Carburetor – Adjust
Air Cleaner – Damage in Shipment
Fuel Pump – R & R
Intake Manifold
Injectors/Fuel Rail
0.8
1.2
0.5
0.3
0.3
1.0
–
0.8
1.2
0.5
0.3
0.3
1.0
–
0.5
1.0
0.3
0.3
0.3
2.0
–
0.7
1.0
0.3
0.3
0.3
2.0
1.5
4050
4051
4052

1

A
Time allowed is for each cylinder.
Additional 0.5 for 2nd cylinder.

Additional 0.5 for EFI engines.
24
Courage
Twin
ECU-Engine Control Unit; TPS-Throttle Position Sensor.
Plated cylinders cannot be rebored.
Maximum Time (Hr.)
Courage Twin, Courage PRO Twin,
& Aegis Flat Rate Schedule
Job No.
4080
4082
4083
4084
4085
4086
4087
4088
4089
4090
4091
4094
4095
4097
Description
Miscellaneous Repairs
Cylinder Head and/or Gasket – Replace/each
Shrouds only – R & R
Oil Pan, Closure Plate, and/or Gasket – Replace
Muffler – Replace
Governor – Adjustment
Governor R & R
Oil Pump R & R
Crankshaft – Grinding (ENTER NET COST)
Crankcase – Boring (ENTER NET COST)
Governor Seal Replacement
Oil Sentry/Oil Temp./Oxygen Sensor
Adjust Belt Tension
Flywheel Cover
Breather Cover R & R
Courage
PRO Twin
SV710-740
SV810-840
1.0
0.5
1.0
0.3
0.5
1.5
1.5
–
–
0.8
0.2
–
–
–

1

A
Time allowed is for each cylinder.
Additional 0.5 for 2nd cylinder.

Additional 0.5 for EFI engines.
Courage
Twin
1.0
0.5
1.0
0.3
0.5
1.5
1.5
–
–
0.8
0.2
–
–
–
Aegis
LV560-680
3.3
–
1.0
0.3
0.5
1.5
1.5
–
–
0.8
0.3
–
2.3
–
LH630-775
2.5
0.3
1.0
0.3
0.5
1.5
1.5
–
–
0.8
0.3
0.7
–
–
ECU-Engine Control Unit; TPS-Throttle Position Sensor.
Plated cylinders cannot be rebored.
25
OHC Flat Rate Schedule
Job No.
4000
4010
4011
4012
4013
4015
4016
4020
4021
4022
4023
4029
4030
4031
4033
4034
4035
4037
4038
4039
4046
4047
Camshaft & Valves
Valve R & R (No Grinding)
Valve Tappet Adjustment
Valve Grinding
Valve Spring Replacement
Valve Cover Gasket and/or Breather
Camshaft R & R
Camshaft PTO Seal
Timing Belt R & R
Rocker Arm
Ignition
Ignition Module R & R (Includes Both Modules)
Flywheel R & R
TH16
TH18
2.5
3.0
4.0
5.0
4.0
3.0
3.5
2.5
3.0
4.0
5.0
4.0
3.0
3.5
3.0
0.5
2.0
3.0
3.0
0.5
2.0
3.0
4.0
0.5
4.0
2.5
0.5
2.5
2.0
1.5
2.5
4.0
0.5
4.0
2.5
0.5
2.5
2.0
1.5
2.5
1.5
0.7
1.5
0.7
0.5
1.0
0.5
1.0
0.5
0.5
1.0
1.0
0.3
0.5
0.5
1.0
1.0
0.3
4070
4071
4072
4073
4074
4075
1.0
1.0
0.3
0.1
0.5
0.5
1.0
1.0
0.3
0.1
0.5
0.5
4082
4083
4084
4085
4086
4087
4088
4089
4090
Miscellaneous Repairs
Shrouds only – R & R
Oil Pan, Closure Plate, and/or Gasket – Replace
Muffler – Replace
Governor – Adjustment
Governor R & R
Oil Pump R & R
Crankshaft – Grinding (ENTER NET COST)
Crankcase – Boring (ENTER NET COST)
Governor Seal Replacement
0.7
3.0
0.3
0.5
2.5
2.0
–
A
0.8
0.7
3.0
0.3
0.5
2.5
2.0
–
A
0.8
4060
4061
4063
4064
4065
Crankcase cannot be rebored
26
Twin
Charging
Regulator – Test & Replace
Stator – Test & Replace (Includes Flywheel R & R)
Starter
Retractable – R & R, Replace Rope & Spring
Starting Motor – Bendix Type R & R
Starter – Bendix Rebuild (Includes R & R)
Starter Drive R & R
Starter Solenoid R & R
Carburetor & Air Intake
Carburetor R & R
Carburetor – Rebuild (Includes R & R)
Carburetor – Adjust
Air Cleaner – Damage in Shipment
Fuel Tank – R & R
Fuel Pump – R & R
4050
4051
A
Description
Major Repairs
Engine R & R
Short Block Replacement
Miniblock/Crankcase
Major Overhaul (Includes Valve Service)
Minor Overhaul (Excludes Valve Service)
Connecting Rod
Piston and/or Rings
Crankshaft
Crankshaft & Main Bearing R & R
Crankshaft – PTO Seal
Crankshaft – Flywheel Seal
Crankshaft & Connecting Rod
Maximum Time (Hr.)
Magnum Flat Rate Schedule
Job No.
Description
Maximum Time (Hr.)
Single
Twin
M8,M10,
M12,M14,M16
MV16,MV18,MV20
M18 & M20
4000
4001
4002
4010
4011
4012
4013
4015
4016
Major Repairs
Engine R & R
Generator Set R & R – Motor Home
Engine R & R From Generator Set
Short Block Replacement
Miniblock Replacement
Major Overhaul (Includes Valve Service)
Minor Overhaul (Excludes Valve Service)
Connecting Rod
Piston and/or Rings
1.0
2.0
1.0
3.0
3.5
5.0
4.0
2.0
2.0
2.5
–
–
3.0
–
6.0
5.0
5.0
3.0
2.5
2.0
3.0
3.0
–
6.0
5.0
5.0
3.0
4020
4021
4022
4023
4024
Crankshaft
Crankshaft & Main Bearing R & R
Crankshaft – PTO Seal
Crankshaft – Flywheel Seal
Crankshaft & Connecting Rod
Balance Gears – R & R
3.0
0.5
1.5
3.0
3.0
5.0
1.5
1.5
5.0
–
5.0
0.8
1.5
5.0
–
4029
4030
4031
4032
4033
4034
4035
Camshaft & Valves
Valve R & R (No Grinding) (Each Cylinder)
Valve Tappet Adjustment
Valve Grinding (Each Cylinder)
Valve Guide Replacement
Valve Spring Replacement
Valve Cover Gasket and/or Breather
Camshaft R & R
1.0
1.0
1.2
1.5
1.0
0.5
3.2
1.0
1.0
1.2
1.5
1.0
0.6
4.5
1.0
1.0
1.2
1.5
1.0
0.6
4.5
4046
4047
Ignition
Ignition Module R & R
Flywheel R & R
1.0
1.2
1.0
1.2
1.0
1.2
0.5
1.5
0.5
1.5
1.0
1.5
4060
4061
4063
4064
4065
Charging
Regulator – Test & Replace
Stator – Test & Replace (Includes Flywheel R & R)
Starter
Retractable – R & R, Replace Rope & Spring
Starting Motor – Bendix Type R & R
Starter – Bendix Rebuild (Includes R & R)
Starter Drive R & R
Starter Solenoid R & R
1.0
1.0
1.5
1.2
0.5
1.0
0.5
1.0
1.2
0.5
–
1.0
1.5
1.2
0.5
4070
4071
4072
4073
4074
4075
4076
Carburetor & Air Intake
Carburetor R & R
Carburetor – Rebuild (Includes R & R)
Carburetor – Adjust
Air Cleaner – Damage in Shipment
Fuel Tank – R & R
Fuel Pump – R & R
Fuel Pump – Rebuild (Includes R & R)
1.0
1.5
0.2
0.3
0.5
0.5
1.0
0.5
1.0
0.3
0.3
–
0.3
0.8
0.5
1.0
0.3
0.3
–
0.3
0.8
4080
4081
4082
4083
4084
4085
4086
4087
4088
4089
Miscellaneous Repairs
Cylinder Head and/or Gasket – Replace/each
Cylinder Head Retorque
Shrouds only – R & R
Oil Pan and/or Gasket – Replace
Muffler – Replace
Governor – Adjustment
Governor R & R
Oil Pump R & R
Crankshaft – Grinding (ENTER NET COST)
Crankcase – Boring (ENTER NET COST)
1.0
0.8
0.6
0.5
0.3
0.5
3.0
–
–
–
0.6
0.4
0.6
1.0
0.3
0.3
4.3
2.0
–
–
0.6
0.4
0.6
–
0.3
0.3
4.3
2.0
–
–
4050
4051
27
Maximum Time (Hr.)
Single
K-Series Flat Rate Schedule
Twin
K91,
K161,K181 K241,K301,K321,K341 KT17,KT19
Job No.
Std.
Q
Std. & Q
K582
Std. & Q♣
Major Repairs
Engine R & R
Generator Set R & R – Motor Home
Engine R & R from Generator Set
Short Block Replacement
Miniblock Replacement
Major Overhaul (Includes Valve Service)
Minor Overhaul (Excludes Valve Service)
Bare Block
Connecting Rod
Piston and/or Rings
1.0
2.0
1.0
3.0—
3.5—
5.0
4.0
4.0œ
2.0
2.0
1.0
2.0
1.0
3.0
3.5
5.0
4.0
–
2.0
2.0
1.5
2.0
1.0
3.2
3.7
5.5
4.2
–
2.2
2.2
2.5
2.0
2.0
3.0
–
6.0
5.0
–
5.0
3.0
3.5
2.0
2.5
5.0
–
8.0
6.5
7.0
3.5
3.5
4020
4021
4022
4023
4024
Crankshaft
Crankshaft & Main Bearing R & R
Crankshaft – PTO Seal
Crankshaft – Flywheel Seal
Crankshaft & Connecting Rod
Balance Gears – R & R
3.0
0.5
1.5
3.0
–
3.0
0.5
1.5
3.0
3.0
3.2
0.5
1.7
3.2
3.2
5.0
0.8
1.5
5.0
–
3.0
0.8
2.0
3.5
–
1.0
1.0
1.2
0.5♠
1.0
0.5
3.0
1.0
0.5
1.2
0.5
1.0
0.5
3.2
1.2
0.6
1.4
0.7
1.2
0.5
3.4
1.0
1.0
1.2
0.8
1.0
0.6
4.5
1.5
1.0
1.7
0.8
1.5
0.5
3.0
0.3
0.5
0.2
0.2
1.0
0.3
1.0
1.0
0.3
0.5
0.2
0.2
1.0
0.3
1.0
1.0
0.3
0.5
0.2
0.2
1.0
0.3
1.0
1.0
0.5
0.5
0.2
0.2
–
0.3
–
1.0
0.5
0.5
0.2
0.2
–
0.4
–
1.0
4040
4041
4042
4043
4044
4045
4046
4047
Camshaft & Valves
Valve R & R (No Grinding) (Each Cylinder)
Valve Tappet Adjustment
Valve Grinding (Each Cylinder)
Valve Guide Replacement
Valve Spring Replacement
Valve Cover Gasket and/or Breather
Camshaft R & R
Ignition
Ignition Timing
Points and/or Condenser – Replace & Adjust
Shipping Damaged Spark Plug – Replace & Adjust
Spark Plug Wire – Replace (Battery Ignition)
Spark Plug Wire – Replace (Magneto Ignition)
Ignition Coil – Replace
Magneto Coil – Test & Replace (Includes Flywheel R & R)
Flywheel R & R
4050
4051
Charging
Regulator – Test & Replace
Stator – Test & Replace (Includes Flywheel R & R)
0.5
1.0
0.5
1.0
0.5
1.0
1.0
1.5
0.5
1.5
4060
4061
4063
4064
4065
Starter
Retractable – R & R, Replace Rope & Spring
Starting Motor – Bendix Type R & R
Starter – Rebuild (Includes R & R)
Starter Drive R & R
Starter Solenoid R & R
1.0
0.5
1.0
0.5
0.5
1.0
0.5
1.0
0.5
0.5
1.0
0.5
1.0
0.5
0.5
–
0.5
1.0
0.5
0.5
–
1.0
1.0
0.5
0.5
0.5
1.0
0.3
0.3
0.3
0.3
0.5
1.0
0.3
0.3
0.3
0.3
0.5
1.0
0.3
0.3
0.3
0.3
0.5
1.0
0.3
0.3
–
0.3
0.5
1.0
0.3
0.3
–
0.3
0.5
0.3
0.2
0.5
0.3
0.5
3.0
–
–
–
0.5
0.3
0.2
0.5
0.3
0.5
3.0
–
–
–
0.5
0.3
0.4
0.5
0.3
0.5
3.7
–
–
–
0.6
0.7
0.5
–
0.3
0.3
4.3
2.0
–
–
0.6
0.7
0.5
0.5
0.3
0.7
1.5
3.0
–
–
4070
4071
4072
4073
4074
4075
4080
4081
4082
4083
4084
4085
4086
4087
4088
4089
Carburetor & Air Intake
Carburetor R & R
Carburetor – Rebuild (Includes R & R)
Carburetor – Adjust
Air Cleaner – Damage in Shipment
Fuel Tank – R & R
Fuel Pump – R & R
Miscellaneous Repairs
Cylinder Head and/or Gasket – Replace/each
Cylinder Head Retorque
Shrouds only – R & R
Oil Pan and/or Gasket – Replace
Muffler – Replacement
Governor – Adjustment
Governor Replacement
Oil Pump Replacement
Crankshaft – Grinding (ENTER NET COST)
Crankcase – Boring (ENTER NET COST)
K141,K161,K181 only
28
Std.
♣
4000
4001
4002
4010
4011
4012
4013
4014
4015
4016
4029
4030
4031
4032
4033
4034
4035
—
Description
♣
29
Carburetor Replacement Evaluation Form
(Attach to Warranty Claim)
Dealer:
Inspector:
Inspection Date:
Model:
Serial:
Spec:
Warranty Claim:
Carburetor No.:
EWR:
Purpose: Please read the Symptoms Observed below and complete only the section that applies to the carburetor failure. This
form must be filled out each time a warranty claim is submitted for a replacement carburetor. Any claims submitted
without this form attached will be returned.
Symptoms Observed
Cranks But Does Not Start
Check carburetor solenoid operation.
Check fuel supply.
Dies After Starting
2
Check fuel quality.
Check fuel supply to carburetor.
Check fuel tank venting.
Check carburetor solenoid operation.
Idles Rough/Misfires
2
Check fuel quality.
Check for intake leaks.
Check for dirt/debris in carburetor jets.
Check carburetor O-Rings.
Verify fuel shut-off solenoid is operational.
Hunts/Surges
2
Check fuel quality.
Check governor and speed settings.
Check for linkage interferences.
Check for dirt/debris in carburetor (lean condition).
Check accelerator pump diaphragm.
Check fuel pump delivery pressure (1.5 to 2.0 psi).
Black Exhaust Smoke (rich condition)
Check choke setting.
3
Check air filter.
Check accelerator pump for leakage (clamp hose to test).
1,3
Check for carburetor needle and seat leakage.
Check HDAC hose position (L.H. side).
Flooding Carburetor
2
Check fuel quality.
1
Check carburetor needle and seat for leakage.
Check fuel pump pressure (1.5 to 2.0 psi).
After Bang on Shutdown
Ensure engine is shutdown according to proper procedure.
Verify fuel shut-off solenoid is operational.
Check for accelerator pump leakage.
Other
describe
Cause of Failure/Reason Replaced
Poor Load Pickup
2
Check fuel quality.
Check governor and speed settings.
Check for defective accelerator pump.
Check for parasitic loads.
1
If needle/seat is leaking, the recommended cleaning method is to use a cotton swab and mild abrasive to clean the seat.
Rinse the abrasive out of the seat with a suitable cleaner and blow dry with compressed air.
2
Poor fuel quality (dirt, debris, water, etc.) or the lack of maintenance is not covered by warranty.
3
Issues which are caused by dirt are not covered by warranty.
NOTE: Removal of anti-tamper caps will void warranty.
Kohler recommends the use of fuel stabilizers if engines are to be stored for over 30 days.
TP-2570
30
Issued 9/05 Rev. 1/06
31
FORM NO.: TP-2303-J
ISSUED:
12/86
REVISED: 4/08
LITHO IN U.S.A.
FOR SALES AND SERVICE INFORMATION
IN U.S. AND CANADA, CALL 1-800-544-2444
KohlerEngines.com
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
Failure
Analysis
Guidebook
Failure Analysis
I. Introduction
“It couldn’t have run low on oil, I just changed it three
weeks ago.”
“How could it get dirt in it, I blow out the air cleaner
every time I use it.”
Everyone involved in the service of small engines has
heard similar statements at one time or another. It’s
human nature to blame problems on “the machine”, or
on someone else. Therefore, it is important for every
small engine serviceman to develop the ability to
accurately diagnose the cause of an engine failure. If an
incorrect analysis is made, the repair may not remedy
the original cause, and a repeat failure may occur.
If the failure was due to neglect, you should provide an
accurate explanation, so the customer refrains from
making the same error again. The following information
is provided to help you develop your expertise in
analyzing engine failures.
II. Preliminary Examination
Any time an engine comes into your shop for service,
you should begin by making an external examination.
External conditions are often directly related to internal
problems. Even if the engine is only in for routine
maintenance or service, you may find indications that
the customer is not providing adequate care for the
engine and should be advised to change maintenance
practices. If the engine has already failed, the condition
of the exterior may provide valuable insight for
assistance in analyzing an internal failure.
Check the following areas as part of your external
examination.
A. Air Filtration
Figure 1.
Figure 1 shows two sets of parts from the same engine.
The original piston failed from excessive clearance and
slapping. The mechanic didn’t measure the bore for
wear and rebuilt the engine with standard parts. The
bore wear was still present, so the new piston began
slapping and broke up nearly identical to the original.
Some failures are the result of manufacturing defects,
but it is a very small percentage compared to those
which result from normal wear or customer neglect. You
must be able to distinguish the difference to know if a
failure qualifies for warranty consideration.
2
Figure 2.
Figure 2 – Make a thorough examination of the air
cleaner. Remove the outer air cleaner cover and check
it for damage or signs of impact.
Figure 3.
Figure 5.
Figure 3 – Most engines also have an inner cover on
the air cleaner element, which provides backup
protection in case the outer cover gets bumped or
works loose. The inner cover may be a separate piece
of stamped sheet metal, or it may be part of the
element.
Figure 5 – Remove the element cover, if separate
otherwise remove the whole element. If there was no
rubber sleeve on the outer portion of the stud, you
should find one on the inner portion. Check its condition
and look for an imprint or mark on the underside of the
element cover to indicate that it was making contact
and sealing.
Three types of retainers are used on the element cover,
a short rubber sleeve, a lock nut, or a wing nut. Check
that the correct retainer(s) is/are there and tight.
Remove the retainer(s) and look at the stud holes(s) in
the element cover. If the stud holes(s) is/are wallowed
out, it's an indication that the air cleaner components
were loose at some time, and you're liable to find
indications that dust or dirt has bypassed the system,
as you continue your analysis.
Figure 6.
Figure 6 – Is the air cleaner element dirty, plugged, or
damaged? Is it a genuine factory part?
Figure 4.
Figure 4 – Carefully remove the precleaner. Check it
for tears or deterioration. Does it look like it's been
serviced regularly, at the recommended 25 hour
interval?
3
Figure 7.
Figure 9.
Figure 7 – Take a close look at the element sealing
surfaces. Are there any dirt tracks across the sealing
surface indicating leakage? Have the reinforcing wires
punctured the rubber seal? If so, it indicates that the
cover was overtightened. Protruding wires could allow
leakage. This air cleaner element is obviously damaged.
Note the crushed wire mesh. This is an example of an
element that can not properly seal out dirt and debris.
The lesson here is to check the sealing area of the
paper element and the wire mesh for signs of damage
due to over tightening, damage or abuse.
Figure 9 – Check the inner portion of the air cleaner
base plate and the carburetor throat for signs of dust or
dirt. If any traces are found, recheck all of the air
cleaner components to determine the source of dirt
entry. Perhaps the breather hose was pulled loose from
the base plate, allowing dirty entry through the hole.
B. Oil
Figure 10.
Figure 8.
Figure 8 – Check the element with a light for punctures
in the paper filtering material. If you cannot see any light
at the base of the creases, the filter should be replaced.
4
Figure 10 – Pull the dipstick and check the oil. Look at
the level of oil, but also note the color and consistency
of the oil. Is it fresh, clean oil that was added after a
failure? Or, perhaps, it’s so thick and dirty it won’t drip
off the stick because it hasn’t been changed in 150 or
200 hours. When you drain the oil, measure the amount
that you drain out and examine it closely. Notice again
the color and consistency. Does it have an abnormal
smell? Do you see any metal chips or wear particles?
Do you notice any sludge? If the engine has an oil filter,
notice whether is a genuine factory part.
C. External Surfaces
Figure 13.
Figure 11.
Figure 11 – Check the overall condition of the exterior.
Is the outside relatively clean, or is there an
accumulation of oil, dirt, chaff, etc.? Are there any visible
oil leaks? Also check for any indication that the engine
may have been disassembled or repaired previously.
Figure 13 – What about the cooling fins? The engine
needs adequate air flow across the cooling fins to
dissipate heat.
E. Carburetor and Intake
D. Cooling System
Figure 14.
Figure 12.
Figure 12 – Is the grass screen plugged or restricted,
possibly contributing to overheating?
Figure 14 – Carefully examine the carburetor and the
intake manifold. Is anything broken or loose? Is there
dirt or debris in the manifold/intake area? Are the
mounting gaskets in the right location and are they the
right ones?
5
F. Governor Components
If a major failure has occurred, this form should be filled
out before your distributor representative arrives to
make the warranty analysis inspection.
III. Disassembly
You are now ready to proceed with the disassembly and
failure analysis inspection procedures. During
disassembly, there are, again, specific areas that should
have investigative attention.
A. Peripheral Parts
Figure 15.
Figure 15 – Check the external governor components
and linkages. Are any of the pieces bent, broken, or
missing? Have any non-factory modifications been
made?
Figure 17.
Figure 17 – After the shrouds have been removed,
check the cooling fins and cylinder block surfaces that
were not visible earlier. Note any additional findings on
the Engine Inspection Data Record.
Figure 16.
Figure 16 – Operate the throttle control and check
whether the mechanism can move freely through its
normal range. Check the initial governor adjustment
setting. Also note the position of the governor spring.
Has it been moved?
G. Final Check
Finally, in addition to the air cleaner system which has
already been checked, look for any other possible
point(s) where dirt or contamination may have entered
the engine.
The conditions found during your preliminary
examination should be noted for future reference. The
Engine Inspection Data Record, TP-2435, is available
from Kohler Co. to record your findings (see sample at
back of book).
6
Figure 18.
Figure 18 – After removing the carburetor, check the
throat of the intake manifold or intake port for traces of
dust, dirt, or other contamination.
B. Cylinder Head
Figure 21.
Figure 19.
Figure 19 – After removal of the spark plug(s) and
cylinder head(s), check the combustion deposits, as
they are often a good indicator of operating conditions.
This head has heavy black oil or gummy-looking
deposits, indicating that the engine was burning oil,
usually from internal wear. This particular engine had so
much oil entering the combustion chamber that it was
starting to flush out the combustion deposits. And the
head hadn't been cleaned for so long that the deposits
completely cover the tip of the spark plug.
Figure 21 – Soft, black, sooty deposits result from
incomplete combustion. They could be due to overrich
carburetor settings, a blocked air filter, or retarded
timing.
Figure 22.
Figure 20.
Figure 20 – Here is another head with similar oily,
glossy-looking deposits. A build-up of crankcase
pressure (breather plugged or inoperative), forcing oil
past the rings, could cause this also.
Figure 22 - Hard, crusty, mottled white deposits result
from high combustion chamber temperatures. They
could be from lean carburetion, an intake air leak,
over-advanced timing, or poor quality gasoline. Deposits
of this type will often be accompanied by a blown head
gasket. The high temperatures and pressures that
cause the white deposits also cause the head to distort
and push the hot exhaust gases past the gasket. If the
engine is operated with the blown gasket, the escaping
hot gases can act like a torch and burn a slot through
the gasket and sometimes even through the head.
7
C. Oil Sump
Figure 24 – This intake valve was removed from an
engine in good operating condition. Notice the bright,
uniform sealing ring around the face. The coke deposits
on the underside of the head and upper stem are
normal for an engine with some running time on it.
Figure 23.
Figure 23 – Check the bottom of the oil sump. A layer of
sludge in the bottom of the engine indicates that
contamination was entering the engine, the oil was not
being changed at the recommended interval, or
incorrect oil was used.
D. Valves
The valves can be very good indicators of various
operating conditions. They should be closely examined
as part of your failure analysis procedure.
The symptoms associated with valve problems include
the following: hard starting, high fuel consumption, poor
compression and loss of power, or the engine will pop
and stall after a period of running. The most common
problems related to valves are burning, sticking and
valve erosion.
Figure 25.
Figure 25 – This engine was also in satisfactory running
condition. However, you will notice that the “coking” is
significantly worse. Possible contributing factors are:
prolonged periods of idling, continuous duty at light load,
“lugging” the engine during operation, running with a
restricted air cleaner, or valve stem and guide wear.
The deposits are not yet interfering with normal
operation, but they could if allowed to accumulate much
more.
To help distinguish good from bad, we have included
some examples of both.
Figure 26.
Figure 24.
8
Figure 26 – This is an exhaust valve from an engine in
good operating condition. Again, note a good sealing
ring on the face. Relatively light, brownish deposits
indicate good operating conditions. An engine running
under proper conditions will usually have light brown,
brown, or gray deposits.
Figure 27.
Figure 29.
Figure 27 – The white deposits, seen here, indicate
very high combustion temperatures, usually due to a
lean fuel mixture. The engine had only run for a short
time, so the faces have not yet started to burn, but you
will note that the sealing ring has already started to
deteriorate.
Figure 29 – Valve burning will also occur if there are
conditions present which prevent the valve from closing
or sealing properly. Here we see deposit accumulation
around the entire circumference of the face. This would
normally indicate that the valve was not closing
completely. Perhaps the tappet clearance was
incorrectly set, or combustion deposits may have flaked
loose in the head and lodged between the valve and
seat. Because the valve is not sealing, it will start to
burn with continued operation.
Figure 28.
Figure 28 – Continued operation with high combustion
temperatures will result in more severe burning and
deterioration of the valve face.
Figure 30.
Figure 30 – When the exhaust valve is burned, or not
sealing, the fuel burn is no longer contained within the
combustion chamber. Each time the engine fires, a
burst of flame passes the valve. As the face continues
to burn and deteriorate, the combustion leakage begins
to act like a torch. The valve material on the underside
of the head and neck begins to burn away, a condition
referred to as valve erosion.
9
The burned oil deposits normally responsible for valve
sticking are due to elevated temperatures in the valve
guide area. The problem will usually show up during hot
weather, especially on an engine that doesn’t get
adequate maintenance.
Figure 31.
Figure 31 – If the initial valve burning was due to
extreme combustion temperatures (lean mixture, etc.),
the blistered white deposits may also show up in the
area of erosion.
Figure 33.
Figure 33 – If a valve stem shows signs of abrasive
material or scoring, check the carburetor inlet and air
cleaner base for signs of dirt bypassing the air filter or
precleaner.
Figure 32.
Figure 32 – Another, fairly common valve-related
problem is valve sticking. It is usually caused by an
accumulation of burned oil deposits on the valve stem
and in the guide.
The customer will usually complain that the engine runs
anywhere from 15 to 90 minutes, then loses power or
“pops” out the exhaust and stalls. It normally will not
restart until the engine cools for 10-15 minutes and a
metallic snap is heard.
10
Figure 34.
Figure 34 – If your preliminary examination of the
engine indicated the possibility of dust or dirt entry,
check the stem of the intake valve(s) for further
confirmation. The valve stems should appear shiny like
the one on the left. If contamination has been entering
through the air intake, the stems will have dull wear
patterns where they travel in the guides.
Leave the parts in their original state as much as
possible, until the failure analysis procedure has been
completed. Do not clean anything unless it is necessary
to make an accurate inspection.
IV. Analyzing the Failure
A. Pistons and Rings
Figure 35.
Figure 35 – In this example, the dirt entry was due to a
leaking remote air filtration system. Again notice the
“buffed” appearance of the valve stem.
Also notice the air cleaner hose which was used. Wire
reinforced hose should never be used with a remote air
cleaner. The wire does not compress under the clamps,
preventing a good seal, and allowing unfiltered air to
enter at the joints.
E. Major Components
The cylinder/crankcase, crankshaft, connecting rod, and
piston assembly are usually considered to be the major
components of an engine. They are the parts that
confine the energy of combustion and transmit the
power of that energy to the piece of equipment to
perform work. Because of the tremendous forces and
stresses they must withstand, they are the components
with the most critical running tolerances. They are also
the components most subject to failure.
Figure 37.
Figure 37 – Problems relating to the piston and rings
will usually fall into one of two categories, excessive
wear or piston seizure.
Figure 38.
Figure 36.
Figure 36 – Be careful when disassembling the major
components, so you do not disturb or destroy any
critical evidence.
Figure 38 – Excessive wear can often be detected
visually, even before any measurements are taken.
From normal operation, the wear pattern on the thrust
face of a piston will cover about 20-40% of the face. If it
cover 50% or more, with visible vertical scratches, you
know there has been contamination between the piston
and cylinder wall causing excessive wear.
The erosion at the very top edge of the piston is also
due to the wear. As the rings wear, oil consumption
increases resulting in more combustion deposits, and a
carbon ridge forms at the top of the cylinder.
11
In the area near the exhaust valve, the carbon becomes
very hard and abrasive from the exhaust temperatures.
When the piston repeatedly hits those hard deposits, the
material is gradually eaten away. The newer Mahle
pistons, used in most Kohler engines today, have the
top land machined to a smaller diameter to allow more
clearance and help prevent this type of damage.
Figure 41.
Figure 41 – On the other hand, heavy ring wear, with
little or no bore wear, indicates that high operating
temperatures were present, but little or no dirt.
Figure 39.
Figure 39 – Damage from contamination entering an
engine can occur over an extended period of time with
very slight leakage, or it can be quite rapid, if a
significant amount of dirt is entering. This damage
occurred in just 15 hours of running from ingesting
about 1/4 teaspoon of dust per hour.
If a customer punctured their air cleaner element by
using compressed air, or assembled the air cleaner
incorrectly, that the element was not sealing, then ran
the engine for a week or two before discovering the
error, the engine could already be worn beyond
acceptable limits.
Figure 40.
Figure 40 – If the engine is running hot (blocked screen
or fins) and ingesting dirt at the same time, the wear will
occur even more rapidly. This Command engine was
completely worn out after just 125 hours of operation.
The oil ring rails are so badly worn that the expander
was rubbing the cylinder walls.
12
Figure 42.
Figure 42 – If a customer ignores the first signs of wear
(oil consumption and blue exhaust smoke) and
continues to run the engine, the wear will progress to
the point that the piston begins to “slap” because of the
excessive running clearance. The piston slap puts
increased stress on the piston skirts and they can begin
to crack.
Figure 43.
Figure 46.
Figure 43 – With continued operation, the cracks will
progress across the thrust face and/or up toward the oil
ring groove.
Figure 46 – A customer that doesn’t maintain a twin
cylinder engine ends up with double trouble.
Figure 47.
Figure 44.
Figure 44 – In some cases, just the lower portion of the
skirt will break off.
Figure 47 – This engine ran for only 6 hours following a
rebuild. The piston ring end gaps go as high as .042 in.,
and the crankpin was .007 in. undersize.
Always scrub the cylinder with hot water, detergent, and
a brush after it has been bored or honed. Use sufficient
detergent to provide good sudsing action. This way, you
can be certain that the machining oil is broken down to
allow complete removal of the grit particles from the
pores of the iron.
Figure 45.
Figure 45 – In other cases the whole piston will break
up. The customer will not be able to ignore it any longer.
13
Figure 48.
Figure 50.
Figure 48 – On a single cylinder block, also be certain
to clean and flush out the oil drain hole which goes from
the valve chamber into the cylinder.
Figure 50 – The scoring on a seized piston is
sometimes just on the primary thrust face. Look at the
opposite thrust face and the sides for other possible
indicators.
Figure 49.
Figure 51.
Figure 49 – Piston seizure is also visually obvious, but it
can be a little more difficult to analyze. There are a
number of possible causes, but the appearance doesn’t
vary much from one to another. Possible causes include
overheating from insufficient cooling air, lack of
lubrication, insufficient running clearance, oil additives,
and contamination or foreign material in the engine. This
is one instance where your preliminary examination may
be very helpful. Did you find dirty, thick oxidized oil in the
engine? Was the cooling system restricted?
You may also find other indicators on other portions of
the seized piston.
14
Figure 51 – This piston shows evidence of overheating.
Notice the dark brown deposits as well as the blackened
area near the wrist pin. This is severely overheated oil
starting to bake. Your next challenge would be to see
what is causing this condition.
Figure 52.
Figure 54.
Figure 52 – This engine had high combustion
temperatures and restricted cooling, resulting in very
black, scorched deposits.
Figure 54 – If the piston has signs of overheating and/
or oxidized oil, look at the governor gear and breather
filter for further confirmation. The governor gear takes
on a dark orange or rust color when exposed to
overheated oil. The breather filter will also be discolored
with burned oil deposits. In severe cases it may be so
brittle that it crumbles.
Figure 53.
Figure 53 – Severe oxidation or use of an oil additive
can cause a complete breakdown of the oil. The
deposits will appear to be a cross between axle grease
and tar.
Figure 55.
Figure 55 – Seizures due to insufficient running
clearance will usually result in scoring without any other
signs. The scoring may show up on both thrust faces,
heavier on the primary face (toward the valves).
B. Connecting Rods
Connecting rod failures will provide some of the greatest
challenges to your failure analysis expertise. Sometimes
the indicators will be pretty clear. However, in other
cases, they may be difficult to spot, or there may be two
or three indicators that seem to contradict each other.
The rod may be broken in such small pieces that it’s
difficult to find any failure indicators.
Your preliminary examination of the engine may provide
some valuable assistance where the rod failure
indicators are elusive or unclear.
15
To correctly analyze rod failures, you will need to identify
both. The similarities will usually help you determine a
general failure category (lack of oil, manufacturing
defect, etc.). The differences will help you distinguish
one from another, and often provide clues to the
circumstances or conditions that caused that particular
failure.
Where, then, should we look to determine the cause of
failure? Actually there are four areas that should be
scrutinized before a decision is made.
Figure 56.
Figure 56 – There are many different failure modes on
connecting rods, but some of them are more common
or prevalent than others. A few years ago, a task force
at Kohler Co. analyzed more than 400 connecting rod
failures. When they compiled their data, nearly 75% of
the failures they had looked at were similar to the rod in
this photo, so this could be considered a "typical"
connecting rod failure.
The connecting rod had seized onto the crankshaft,
melting and searing the aluminum on the bearing
surface in the process. The exterior surfaces are dark,
with burned oil deposits around the journal area. Often,
the burned oil deposits will extend part way up the beam
and down onto the dipper (if it's a splash-lube rod). The
rod may be fractured, possibly a single break, or several
pieces, Sometimes, on twin cylinder engines, the engine
keeps on running on the opposite cylinder after one rod
has failed, and the broken rod gets smashed into many
tiny fragments. Those are probably the most difficult to
analyze, because the pieces are so small it's difficult to
find and identify any good failure indicators.
Figure 58.
Figure 58 – The first area to examine is the journal area
and the dipper (if it has one). Did the rod seize, causing
the aluminum on the bearing surface to smear and
transfer? Is the outside of the journal area discolored/
darkened? Are there burned oil deposits present? Do
the burned oil deposits extend down onto the dipper?
What is the condition of the dipper (intact, broken,
nicked or scraped, discolored)?
The first rod on the left is very similar to Figure 56. It
seized on the crank and it has burned oil deposits on
the outside of the journal. A seizure results when there
is inadequate lubrication between the crankshaft and
the rod. The burned oil deposits indicate there was
some oil present, but it wasn't providing adequate
lubrication. The engine was probably run low on oil.
The second rod had some running time, but it never had
failure or problem. It is included in the photograph to
help you distinguish color variations.
Figure 57.
Figure 57 – All of these rods failed by seizing onto the
crankpin. While there are many similarities, if you look
closely, there are also some subtle differences.
16
The third rod has a broken dipper. The lighter color of
the broken segment indicates that the break occurred
before the rod seized. In fact, the broken dipper caused
the failure. If the color had been the same on both sides
of the break, it would have indicated that the dipper
broke after the seizure and the cause of failure would
have to be found elsewhere.
The last rod came from an engine that was started with
no oil. The bearing surface is smeared, and the rod is
darkened from the heat of the seizure, but there are no
burned oil deposits because there was no oil present.
Figure 61.
Figure 59.
Figure 59 – If the dipper is broken, look closely at the
break surface. Is it a tensile break or a fatigue break?
Figure 61 – A fatigue break usually results from
damage done prior to, or during assembly. If the rod is
dropped on the dipper, or the dipper is bumped against
the workbench, a small stress crack can be created in
the aluminum. The forces of operation, along with
repeated heating and cooling, will cause increased
metal fatigue around the crack. The crack will spread
until the dipper finally separates and drops into the oil
pan.
Figure 60.
Figure 60 – A tensile break results from a single sharp
blow that breaks off the dipper. The dipper will have a
nick or scrape where it was hit, and the break surface
will be quite rough, because the metal has been torn
apart. You might also notice a "feather" pattern, which
can indicate the direction of the breaking force.
Figure 62.
Figure 62 – After the dipper drops off, the rod will seize
because the oil is no longer being circulated to the
bearing surface. The high friction temperatures
generated during seizure cause the oil to burn around
the journal area and down to the break line. A definite
color variation will be obvious at the break line.
17
Figure 65 – The second area of examination is the
bearing surface of the rod. The bearing surface will
often be smeared, but it can still reveal clues about the
conditions at the time of failure. These two rod caps are
a good example. Notice the difference in color.
The cap on the right has streaks of burned oil blended
with the smeared aluminum, indicating that there was
some oil present, but not enough for adequate
lubrication. It's from an engine that was run low on oil.
The cap on the left has only the bright, smeared
aluminum, no traces of oil. It was from an engine started
without oil.
Figure 63.
Figure 63 – The break surface of a fatigue break will be
smoother than a tensile break. Often the fatigue
process leaves semi-circular markings, called beach
marks, on the break surface. The center of the
markings is the point at which the break originated.
Here the dipper was bumped or damaged from the side.
Figure 66.
Figure 66 – What led up to this failure? If you guessed
it was another engine started without oil, you're right.
Figure 64.
Figure 64 – Examination of this break surface confirms
that it is a fatigue break, and also reveals the cause of
the break, a casting defect.
Figure 67.
Figure 65.
18
Figure 67 – Here you see shiny, smeared aluminum in
the center of the bearing surface, and no discoloration
on the outer surfaces. The failure was due to insufficient
running clearance between the rod and crankshaft. The
rod had been overtightened and the bearing area
collapsed, squeezing out the film of lubricating oil. The
engine had oil in it, which cooled the outer surfaces, but
it couldn’t reach the center of the bearing surface.
Figure 68.
Figure 70.
Figure 68 – The aluminum in a forged connecting rod
appears brighter than a die cast rod. This is a forged rod
that failed from running without oil. The smeared
aluminum is very bright with no burned oil deposits.
Because a forging is stronger than a die casting, you
may also notice some unusual twisting or distortion.
Figure 70 – This rod is from an engine that ran for 15
hours with dirt in the crankcase. The original surface
finish has been worn off leaving a dull, satin
appearance.
Figure 71.
Figure 69.
Figure 69 – If a connecting rod has not seized, the
bearing surface can also be a wear indicator.
The final finishing operation on a connecting rod leaves
a textured, but highly polished surface finish. If there is
dirt in an engine, it combines with the oil and works like
a buffing compound on the bearing surface. The highest
loading occurs at the top and bottom of the stroke, so
the top and bottom of the journal will show wear first.
Figure 71 – If there is a heavy concentration of dirt, or
the particles are large and abrasive (honing grit), you
may see a “dirt” trail around the center of the bearing
surface. The dirt entering through the oil hole gets
pounded into the surface of the aluminum, leaving a trail
around the bearing, in line with the hole.
19
Figure 72.
Figure 74.
Figure 72 – This connecting rod came from the engine
mentioned earlier (Figure 47) where the block was not
cleaned properly after honing. Again note the worn
bearing surface with the abrasive trail in line with the oil
hole.
Figure 74 – The mating surfaces of the connecting rod
are the third area that should be inspected.
Figure 73.
Figure 75.
Figure 73 – This rod came from another engine that
was not cleaned properly prior to rebuilding. After only 6
hours of running, the crankpin was worn .008 in.
undersize. The rod had started pounding because of the
excessive running clearance, causing the aluminum to
begin smearing. The customer became alarmed when
the engine started knocking and losing speed. Within
one more hour of running, a total seizure would have
occurred.
Figure 75 – Here you cannot see any of the saw blade
markings. Instead the mating surface has a hammered
or peened appearance. The rod bolts were not tightened
properly and the peening results from the two sections
of the rod pounding together as the bolts backed out.
20
The machining marks that you see here are normal.
They are made by the saw blade when the rod is out.
Figure 76.
Figure 78.
Figure 76 – Here is another example of
undertightening. In this case, the bolts were just loose
enough for the rod sections to work against each other,
but not loose enough for them to hammer. The result is
a dull gray finish on the mating surface known as
“fretting.” If magnified, this “fretting” would look like the
“peening” you saw in the last slide. This condition will
not be seen on Posi-Lock rods.
Figure 78 – This rod cap shows signs of scoring and
aluminum smearing. If you look closely it has a double
layer of aluminum on the right hand side. This engine
was started with no oil; it seized and was freed up. It
was restarted and shortly after it seized again because
the aluminum transfer from the first seizure left
insufficient running clearance. The lesson here is make
sure there is oil in the engine before starting.
Figure 77.
Figure 79.
Figure 77 – This piece has just a small peened area
near the outer edge of the mating surface. The
looseness here resulted from the high temperatures
generated by the seizure. The bolts had been tightened
properly and only began to yield when the rod started to
seize. This type of peening is secondary. The cause of
the failure was insufficient lubrication.
Figure 79 – This is a shot of a rod bolt that was loose.
This came early within its life cycle. Notice the
elongation of the hole where the bolt comes through.
You can also notice where the bolt wore a groove into
the rod cap.
21
Figure 80.
Figure 82.
Figure 80 – This is a shot of the rod you saw in
Figure 79. Again notice the way the bolt is elongated
and how there is no sign of heat or burned oil.
Figure 82 – Our first example includes a broken
connecting rod and a broken governor gear. The
rod bearing surface looks like it ran without oil. Notice,
however, that the dipper is broken, and not discolored.
The dipper broke first and caused the rod to seize.
But the real culprit here is the governor gear. One of
the roll pins backed out and the flyweight separated
from the gear, breaking the gear in the process. The
flyweight dropped into the oil pan and knocked the
dipper off the rod.
If we had looked at only the rod bearing, we may have
concluded that the engine was run without oil, and we
would have been dead wrong.
Study all of the evidence and be certain that your
decision incorporates everything you see.
Figure 81.
Figure 81 – This connecting rod broke in the beam, but
has no other visible damage and did not seize. When
we look at the break surface, there is no sign of fatigue
or a casting defect, just a tensile break of a good
casting. This failure was caused by engine overspeed.
C. Combination Failures
Many failures involve more than one engine component.
When two or more parts have failed, or been damaged
during failure, analysis can be more difficult.
In those situations, look at each individual component
to see if it actually failed, and why, or if it just received
secondary damage. Then look at the parts collectively.
If more than one part failed, try to develop a logical
sequence. Weigh all of the evidence before making
a decision.
22
Figure 83.
Figure 83 – A high percentage of small engine failures
result from customer neglect. Here you can see the dirty
air cleaner, considerable wear on the piston rings, and
traces of dirty, burned oil on the connecting rod. There is
a color change line on the dipper, but it was only about
3/8 inch from the tip, so the oil level was well below the
“low” mark on the dipstick at the time of failure.
Figure 84.
Figure 86.
Figure 84 – This rod shows signs of aluminum transfer
with burned oil deposits. The rod seized from inadequate
lubrication. As it locked up on the crankshaft, the turning
force of the flywheel and crankshaft caused the
connecting rod to snap in the beam, and tried to pull the
rod apart at the fastener joint. The aluminum thread
transferred to the rod bolt is a secondary occurrence and
not a loose rod bolt.
Figure 86 – This connecting rod shows multiple breaks.
The break in the middle of the beam was a secondary
break; in other words, it occurred after the rod seized to
the crankshaft. The bearing surface indicates that the
initial seizure was from insufficient lubrication.
Figure 87.
Figure 85.
Figure 85 – This rod broke toward the bottom. Notice
the slight smear of aluminum and blackened oil. The
piston shows signs of overheating. This could have
been caused by an improper honing/oversize
procedure, where the piston to bore clearance was too
tight, causing the stress and failure of the connecting
rod. Notice that the rod bolt is sheared.
Figure 87 – Sometimes you may only have a small
amount of evidence to look at to make a determination
as to what happened. This lower rod cap shows some
peening and shifting. This could have been caused by a
loose rod bolt. Again you have to look for other signs,
and/or ask questions of the owner and/or of the engine
itself. In this case the unit had plenty of lubrication. The
failure occurred shortly after an overhaul by a service
technician who forgot to torque the rod bolt to proper
specifications.
23
Figure 88.
Figure 90.
Figure 88 – This is a head assembly from a Command
Engine. Notice the heavy carbon deposit on the face of
the head and valves. The combustion deposits appear
to be wet or shiny. This is an indication that excessive oil
was entering the combustion chamber.
Figure 90 – Here is a close-up of the piston and wrist
pin area. Notice the blackened and burnt deposits in the
wrist pin area as well as the rest of the piston skirt. This
can be caused by multiple factors. Some which would
be poor oil quality, infrequent oil changes and/or
overheating.
Figure 89.
Figure 91.
Figure 89 – This is a close up of a Command head
gasket. Notice the RTV sealant around the return
passages. Someone wanted to get a positive seal
between the head and block and applied RTV. This is
not necessary if the surface areas are clean and dry as
well as making sure there is no warpage. It is also good
practice to check the recommended replacement data
when it comes to the retaining fasteners.
Figure 91 – This is a typical starter motor winding
burned up due to overheating. Again, your job as a
technician is to determine what can cause this to
occur. Was it due to overcranking and not allowing
it to cool down? Was it do to parasitic loads?
Improper voltage, etc.
24
Figure 92.
Figure 93.
Figure 92 - On the crankshafts look for signs of dirt
wear, lack of lubrication and or side loading. Note
condition of all bearing surfaces. In this case, notice the
PTO bearing shows signs of severe scoring. This could
indicate a lubrication or excessive side load problem. It
could also be caused by a faulty electric clutch.
25
You Call the Failure
The following four (4) pictures are parts that have failed.
Take a look at the pictures and try to decide what could have caused each failure.
Figure 96.
Figure 94.
Figure 97.
Figure 95.
26
D. Summary
Failure analysis is an important part of the small engine
repair business. Some failures can be interesting and
challenging. Others can be quite puzzling, almost
exasperating. But if you follow the steps outlined in this
booklet, you’ll be more successful in reaching a logical,
correct decision and completing the proper repair.
Figure 99.
• Carefully disassemble the engine and examine all
of the components. Even though some parts
weren’t involved in the actual failure, they may still
provide some indicators to assist you in reaching a
correct decision. If you are fortunate the location of
the failure is or will be obvious.
Figure 98.
• Make a thorough preliminary examination to help
determine the conditions under which the engine
was operated and pick up any external signs of
factors that may have contributed to the failure. In
some cases, there will be very obvious indicators,
but not always. This engine ran for over two hours,
no load, with no oil in the crankcase, but there are
no external indicators of that.
• Weigh all of the evidence against your experience
as a professional small engine repairman. Your
final decision should incorporate all of the evidence
and provide a logical, sensible explanation for the
failure which occurred. Running an engine out of
gas doesn’t cause a connecting rod failure, but
running it out of oil probably will.
27
Once you have made an assumption,
back up your decision with facts and measurements.
Figure 100. Carbon – Due to what?
Figure 101. Rolled Material – Caused by what?
28
Figure 102. Take Precise Measurements.
Engine Inspection Data Record
To facilitate accurate evaluation:
• enter as much information as possible
• provide as many dimensions as possible.
SECTION 1
•
•
mark location of break or crack on drawing
record conditions found with check mark (X) whenever possible
OWNER AND EQUIPMENT INFORMATION
Owner's Name
Street Address
City
State
Phone No.
(
)
Zip Code
Serial No.
Spec. No.
Model No.
–
Manufacturer of Equipment
Type of Equipment
Date Purchased
Date Failed
Previous Repairs
Warranty Claim No.
YES
Times Used
Hours Used
NO
USAGE/MAINTENANCE INFORMATION
Oil type:
10W-30
10W-40
30W
Hours since last oil change?
5W-20
5W-30
Other
How often is the oil level checked?
Everytime
Must oil be added between changes?
Never
Other
Yes
Was an oil additive used?
Yes
No
What brand?
Yes
Element
How recently?
No
Element:
Yes
No
Precleaner
Element
By whom?
Were any adjustments made to the carburetor or governor?
Yes
How much?
Precleaner
Was it ever replaced or cleaned?
Precleaner:
No
How often is the air cleaner checked?
Customer
No If yes, specify
Dealer
PRELIMINARY EXAMINATION
Air Cleaner Assembly
Type:
Dry
Precleaner
Remote
1. Wing Nut:
Oil Bath
Tri-Phase
Wing nut seal:
Factory Original
Non-standard replacement
Intact
Separated
Missing
2. Outer Cover:
Good condition
Center hole oblong
Other damage (specify)
3. Precleaner:
Clean
Dirty
Plugged
Oiled
Dry
Torn
Other damage
4. Inner Cover:
Retaining seal/nut in place
Center hole oblong
Distorted
Other damage
5. Element:
Clean
Dusty
Dirty
Plugged
Missing
Dry
Non-factory replacement
Other damage
6. Element seals:
Pliable
Hard
Sealing
Leaking
Other damage
7. Air cleaner base:
Tight
Loose
Screw(s) missing
Distorted/Cracked
Breather hose detached
Other damage
Crankcase Oil
1. Amount on dipstick:
Overfilled
Full
2. Condition of oil:
New
Above ‘‘add’’
Used
Below ‘‘add’’
Dirty
No reading
Black
Thick/Sticky
Burnt smelling
Fuel diluted
3. Quantity of oil:
Amount drained:
Observations:
Metal chips present
Sludge present
Amount req'd.
Non-factory oil filter
TP-2435
(Continued on page 2)
29
Preliminary Examination (Cont.)
Cooling System
1. Flywheel Screen:
2. Cooling fins:
Clean
Plugged
Partially blocked (%)
Clean
Plugged
Partially blocked (%)
3. Engine exterior:
Clean
Dirty
Oily
Evidence of prior disassembly or repair
Visible oil leaks (where)
Carburetor and Fuel Supply
1. Condition of carburetor:
Okay
2. Settings:
Broken
Loose
Shafts worn
Dirt in throat
Main fuel adj.
Idle fuel adj.
3. Condition of fuel:
Clean
Fresh
Stale
Contaminated (water, debris, etc.)
Governor
1. Components:
2. Function:
Intact
Missing
Modified
Bent/Broken
Operative
Inoperative
Modified
Misadjusted
Dirt Ingestion
1. Is there evidence of possible dirty entry via:
Air cleaner
Carburetor
Breather
Gasket/Seal
Oil fill opening
Other
Spark Plug
Spark Plug
Cylinder 1
Gap
Cylinder 2
Combustion Deposits
in.
Cylinder 1
Cylinder 2
Light
in.
Make
Heavy
Number
Color
SECTION 2
EVALUATION PERFORMED BY
Evaluator
Date
Company Name
Type of Acct.
Central Distributor
Service Distributor
Service Dealer
Address
State
City
Phone No.
Zip Code
TEAR DOWN ANALYSIS
VALVES
CYLINDER 1
CYLINDER 2
Stuck
Face Burned
Bent
Guide Worn
Not Damaged
CLEARANCE: (COLD)
CYLINDER 1
CYLINDER 2
PISTON RINGS
Intake
in.
in.
Production Rings
Exhaust
in.
in.
Service Rings
CONNECTING ROD
CYLINDER 1
CYLINDER 2
CYLINDER 2
CYLINDER 1
Rings Free in Grooves
Discolored
Rings Stuck in Grooves
Broken
End Gap:
Top
Center
Oil
Bearing Scored
Cap Screws Loose
Dipper Bent
in.
in.
in.
in.
in.
in.
Dipper Broken
Rod Seized to Crankpin
Note: For Crankshaft, Pistons & Cylinder Bore Measurements –
See Page 3.
Rod OK - Not Damaged
2
30
(Continued on page 3)
Tear Down Analysis (continued)
CRANKSHAFT ROD JOURNAL
CYLINDER 1
CYLINDER 1
Left
Middle
Scored
Right
Worn
Unmeasureable
Broken
Not Damaged
Others
Maximum Wear Spec.
CYLINDER 1
X
X
Y
CYLINDER 2
Y
Y
X
MAX. OUT OF
ROUND
Left
Middle
Right
Max. Taper
PISTON
Select the following piston type and measure diameter using appropriate method.
Style A
Style B
Style D
Style C
½"
Measure just below oil ring groove and at right angle to
piston pin.
CYLINDER 1
Style E
½"
Measure 1/2 inch above the bottom of the skirt and at right
angle to piston pin.
CYLINDER 2
Scored
Worn
Cracked
Broken
Ring Grooves Worn
Galled
Discolored
Measure 6 mm (0.24 in.)
above the bottom of piston
skirt at right angles to piston
pin.
CYLINDER 1
CYLINDER 2
CYLINDER 1
CYLINDER 2
CYLINDER 1
CYLINDER 2
Scratched
Not Damaged
Others
Piston Diameter
CYLINDER BORE
Bore Scored
Worn
Not Damaged
Others
MAXIMUM WEAR SPEC.
CYLINDER 1
Y
X
X
CYLINDER 2
Y
MAX. OUT OF
ROUND
Top
Center
Bottom
Max. Taper
3
31
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
FORM NO.: TP-2298-B
ISSUED:
1/79
REVISED: 2/02
MAILED:
LITHO IN U.S.A.